How To: Fix the broken handle of the lid in the leg-area
Posted: Sat Jun 14, 2008 5:05 pm
Ok, so I bought my GrandTour 2 weeks ago.
I noticed the handle was broken of the lid of the small compartment in the floor on the passenger side. Those kind of things just bug me.
Repairing was the solution, but just glueing.....No, it didn't seem to be strong enough to hold. It was broken on the small piece of plastic between the lid and the handle and that is not a big square to use for strength with glue.
It had to be different and when thinking of it, I came up with a solution. Which I might think can come in handy if someone else's handle breaks too.
I am going to make a tutorial, I hope you all find it helpful. If so, maybe one of the Moderators can put it in the tips-section?
The problem: a broken handle on my lid
Here seen is the handle and the lid
I start with removing the lid. Start pulling on the lid from the door to the console. Just pull hard and gentle. Not like a baboon.
Next step is removing the upholstery, do this carefully. Use a wide flat screwdriver and lift little by little. Take your time.
Next is drilling holes through the plastic. Best is to start on the underside of the lid, going up. I used a 0,8mm drill, hand-drilled, so it gives you slight more precision. It is important to drill straight up. Don't push to hard on the drill, it breaks easily.
It should look likes this when you are finished.
A tricky part, hold the handle EXACTLY to the original position and start drilling from the top-part of the lid down. Just make a little marking on the handle, get it off and hand-drill it further straight on the handle. Important is to go straight down again.
When you did drilled one hole, get an extra drill. Put that in the hole and the handle and align it well. Than drill to make a second mark on the handle. This will make it easier to get the metal rods in there.
Important note: Don't drill to deep! drill about the depth of halve the size of the rod you are going to use!
I use the metal pins from a piece of electronic-thingie ( no idea what this used to be, sorry ). The rods are slightly bigger in diameter, which you need to get a better connection and it will hold better.
To make sure, I used Bison-gel for extra-strength. Cover halve of the rod with this gel and stick it in the holes in the handle.
It should look like this, in this picture I also added the gel on the top halve.
Logically; the next step is pushing the rods with the handle in the lid.
Finished, but not quite yet. The carpet needs to get into place.
Use some of the gel and place that on the plastic of the lid, don't use too much ( as I did ) and hold it tightly with your fingers for a few minutes. Let it go and move your hand firm over the upholstery. This should get it back into place.
Unfortunattely I used a little too much gel. Not a big problem, I let it dry and when it is, I can peel the gel parts of. It is a time-consuming job, but needs to be done for the finishing job.
And there we are: a handle back in place. Give the handle some time to cure. Place the lid in the car again. Make sure to start inside out, so start on the console side and then to the door. Make sure to also connect the wires on the connector for the lights in the door. ( if you have them )
Job finished, I hope it is all clear. If there are any questions; please do not hesitate to ask me.
I noticed the handle was broken of the lid of the small compartment in the floor on the passenger side. Those kind of things just bug me.
Repairing was the solution, but just glueing.....No, it didn't seem to be strong enough to hold. It was broken on the small piece of plastic between the lid and the handle and that is not a big square to use for strength with glue.
It had to be different and when thinking of it, I came up with a solution. Which I might think can come in handy if someone else's handle breaks too.
I am going to make a tutorial, I hope you all find it helpful. If so, maybe one of the Moderators can put it in the tips-section?
The problem: a broken handle on my lid
Here seen is the handle and the lid
I start with removing the lid. Start pulling on the lid from the door to the console. Just pull hard and gentle. Not like a baboon.
Next step is removing the upholstery, do this carefully. Use a wide flat screwdriver and lift little by little. Take your time.
Next is drilling holes through the plastic. Best is to start on the underside of the lid, going up. I used a 0,8mm drill, hand-drilled, so it gives you slight more precision. It is important to drill straight up. Don't push to hard on the drill, it breaks easily.
It should look likes this when you are finished.
A tricky part, hold the handle EXACTLY to the original position and start drilling from the top-part of the lid down. Just make a little marking on the handle, get it off and hand-drill it further straight on the handle. Important is to go straight down again.
When you did drilled one hole, get an extra drill. Put that in the hole and the handle and align it well. Than drill to make a second mark on the handle. This will make it easier to get the metal rods in there.
Important note: Don't drill to deep! drill about the depth of halve the size of the rod you are going to use!
I use the metal pins from a piece of electronic-thingie ( no idea what this used to be, sorry ). The rods are slightly bigger in diameter, which you need to get a better connection and it will hold better.
To make sure, I used Bison-gel for extra-strength. Cover halve of the rod with this gel and stick it in the holes in the handle.
It should look like this, in this picture I also added the gel on the top halve.
Logically; the next step is pushing the rods with the handle in the lid.
Finished, but not quite yet. The carpet needs to get into place.
Use some of the gel and place that on the plastic of the lid, don't use too much ( as I did ) and hold it tightly with your fingers for a few minutes. Let it go and move your hand firm over the upholstery. This should get it back into place.
Unfortunattely I used a little too much gel. Not a big problem, I let it dry and when it is, I can peel the gel parts of. It is a time-consuming job, but needs to be done for the finishing job.
And there we are: a handle back in place. Give the handle some time to cure. Place the lid in the car again. Make sure to start inside out, so start on the console side and then to the door. Make sure to also connect the wires on the connector for the lights in the door. ( if you have them )
Job finished, I hope it is all clear. If there are any questions; please do not hesitate to ask me.
One of the consessions to having to make it lower I guess.