As many are aware we've recently replicated the weak plastic factory interior door handle with a cast aluminum replacement for a permanent solution. Now we don't have to read a list of rules and regulations to our passengers before they enter the vehicle. This guide can also be used if you need help removing the interior door panel for any reason







Before you start, you will need:

Tools
-#3, #2, and #1 size screwdrivers
-Allen wrench set (for included bolts)
-Thin plastic or metal spatula (for removing trim pieces)
-Razor/razor knife
-15/64” drill bit and drill


Supplies
-Painters tape
-‘Krazy Glue’ / ‘Super Glue’ gel
-3M Super 77 spray adhesive (or equivalent)



Door Panel Removal

1. Remove plastic door trim by gently popping off flag and lock covers






2. Pry up bolt cover on door cup (paint can opener works great for this) and remove bolt.






3.Gently pry up door cup (flat plastic spatula works great)





4. Remove three exposed panel trim screws

 

5. Gently pop out window switch (plastic spatula works great for this). Remove the short screw from inside the hole where the window switch was (this is the top structural mount
for the handle). Now pop out the screw cap in the center of the door panel and remove the long screw with a #3 Phillips head screw driver (this is the lower structural mount for the handle).






6. The door panel is now free. Lift entire panel straight UP, and out of the upper pin mounts, and remove the door panel.







Door Plastic Removal

1. Remove screws attaching plastic to door panel (left most screw may have a clip)





2. Remove screw attaching lower bracket to plastic spacer.





3. Remove two screws attaching top of handle to trim plastic (see kitty). Remove screws attaching lower door handle to plastic (not shown, near metal bracket). Replacements for these two lower screws (m5) are included with your handle.





3. Separate handle from plastic. The handle and plastic trim is fused together by Mazda with hot plastic at the factory. Score any fused areas with a sharp razor and carefully crack the two piece apart. (One quick motion is best so as not to stress the plastic but quickly break the fused bonds.)





4. Remove handle and bracket from trim plastic. Remove screw from bracket to lower handle. A replacement bolt (m6) is included with your new handle.





Aluminum Handle and Cover Installation
(Note: you can use whatever method you’d like to attach the cover, this is how we did it. Some people used gorilla glue.)

1. Using a razor, slice grip cover neatly down the middle at the seam on the back side. Remove cover.





2. Tape/mask back side of grip cover, and exposed areas of aluminum handle.

 

3. Spray adhesive on back side of grip as well as aluminum handle following directions on can.







4. Apply grip to handle (this will take a few tries to get it to line up correctly). Make sure seam lines up, and wrap the top and bottom of the grip with tape to keep it in place. Add a few dabs of Krazy/Super glue gel to the center of the grip and let set (couple of minutes is all it takes). You may want to hold the seam together while it is curing.





5. Remove the tape and repeat the process to the upper and lower half of the seam. After the grip cover is tacked in place, you may want to neatly run a final bead down the length of the seam. If any texture on the seem is felt afterwards, a razor knife can be used to scrape the seam flat.

6. Using a 15/64” drill bit, enlarge the hole on the bracket to accept the new (included) m6 bolt, and attach the bracket to the handle.





7. Slide the handle with bracket through the door trim plastic, and reattach the two upper screws that were previously removed (take care not to over-tighten any screws going into the door plastic). Now replace the lower bolts (included) that attach the door plastic to the handle.





8. Reattach door plastic to panel, and panel to door. Reassembly is the reverse of removal... simply backtrack through the previous dis-assembly steps).

DONE!!


- Dan and Heath!

 

Now THOSE are some sexy hands

 

Thanks Rich. Hand model with stubby fingers and monkey palms is my night job

 

Kitty sez "nice writeup!" Didn't know you guys were making these, KUDOS for filling a big void!

BTW, my recommendation is to NEVER EVER use power screwdrivers in the FD's interior. The plastic is SO damn brittle that hand tools big time reduce the risk of breaking things and stripping out threads.

Dale

 

Excellent!!!! That little kitten got mad skillz!

 

The power screw driver was only used to remove screws, not re-install them

-Dan

 

Excellent write up. Sticky

 

Can you please include where can I purchase one of those handles? I didn't seem them available on the website.

 

We haven't taken nice product shots yet, so the site hasn't been updated.

If anyone is interested in the handle in either 93 or 94 finish feel free to PM us or write an email to sakebombgarage@gmail.com

Thanks,
Dan

 

I decided not to wrap the aluminum handle. It's now polished instead, something to break the monotony of the plastic.

 

Dope product guys!

 

+1+1+1+1

 

sick!

 

Did you snap some pics? I'd like to see how it looks!

-Dan

 

nice step by step write up.. good job!

 

I 2nd that, if I ever got these door handles I would probably leave them bare metal also. Pics!!

 

I think I may do this to but mostly because of laziness. The problem comes in when the handle gets hot though.

 

Mazda used weak parts to begin with...even on my 32,000 original miles queen, I always tell people to close the passenger door by using the door/window frame.

This is definitely a product that every single FD owner should buy, period.

 

Up! We still have a few of these left in stock. Please PM us if you're interested.

 

Very cool! I'd like to see how it looks without the wrap; just the exposed aluminum. Great write up.

 

To be honest it will be a little narrow without the wrap... I highly suggest wrapping it... it doesn't take that long.

 

I just left it bare aluminum. . .such a solid door handle. . .

 

After seeing this write up I want to do this upgrade. I am also tired of giving people the disclamer of "please don't use that its only for looks."

You sir have a PM