Custom door handle pics

[mnagatani]

So I decided to make my own door handles and took some shots of it during the process. Its made of 2lb foam which is common among house archictecture details. I went to a local shop and the owner game me a scrap for free. It was big enough to crank out two handles. Awesome! I used gorilla adhesive to attach the two mounting bolts on the back side. I just drilled two holes and dropped in the threaded bolts. The whole process took me about two days to complete which is need for drying times for the resin and bondo applications. After doing the first one I learned all about the process. Creating a second door handle to match was a little challenging. The whole cost was very little, but there is some time required. Let me know if you have other questions.

Mike


step 1: initial layout



step 2: first cutout



step 3: rough shaping (most difficult stage to get right)



step 4: used resin to harden foam



step 5: used bondo to get final surface




all finished

[AK F100]

Looks great, good idea.

[Joshpow]

Looks pretty cool. I like the smooth door panels too.

[seattle67]

That's pretty dang cool! Thanks for sharing that.

[KF100TK]

I like it What is the final finish(fabric paint)? How strong and durable do you think it will be?

[mnagatani]

The final surface was the vynl that I used throughout the interior. After the resin, I put a bondo surface to get a smooth feel. I cant say for sure how the durable this will be, but I think its within reason for it to be pretty durable. I wouldn't go hittin a hammer on it, but normal pulling and pushing should be fine. My whole rational to go with the foam was because I could easily shape it. I started with some wood, any boy that just took forever. I dont have or could afford a cnc built product so I went with this concept and hopefully it will be ok.

MIke

[KF100TK]

Thanks mike , keep up the great work very inspiring!

[fordman]

do you have any pics of how you put the bolts in it? those rests look just like the ones on a slick.

[Lightningtruck72]

Outstanding, I might have to give something like that a shot. Right now I have door handle/arm rest out of a 89 foxbody mustang for the power window switches, but they look like ass.

[mnagatani]

Fordman,

I dont have any pics of how the bolts sit in there, but basicly I drilled down about 1" into the foam and dropped some "gorrila" glue into the hole. I then put a threaded bolt into the hole and waited the next day to let it cure and it was good to go.

MIke

[Robert]

Mike the resin didnt melt the foam