Passenger Side Door Handle
 

Hey guys, question.

My door handle, partially came out (pic below)


https://cimg7.ibsrv.net/gimg/www.rx8...6a34b2ebc2.jpg


Broke?


However, when I look around for a replacement, I see this..

Mazda RX8 Left Driver Front Door Handle Black 2004 2005 2006 2007 2008 | eBay

This looks just like my current handle... All other handles I see on ebay either look the same or look completely different. Any guidance on what I should do? Or should I just go ahead and take off the door panel and investigate first before coming to a conclusion?

Was figuring one of you guys could guide me towards the right direction. Thanks a bunch! Yes, I used the search function, but didn't really find the exact issue, the door handle inside of the car works just fine and before this happened, it worked just fine.

The issue "began", when my gf tried to open the door mid unlock, after that it felt as if the handle was loose. Thanks again!

I think the part that came all the way out on your handle is where it connects to the opening mechanism, so...open your door and take a look first. The actual handle looks fine. Maybe the bolts just wiggled out? Good luck

That's what I'm hoping ^^^ Thanks for your diagnosis, from what I could tell, nothing is broke yet. I'll take it apart this weekend, thanks again man!

Is likely not the handle that broke, is the other part. I have repaired 3 on different cars. If you are comfortable with fiberglass resin, and part is not destroyed, it is a fiddly repair, but not hard. Once you get it out, you will see what broke. The spring broke off the part it rests against.

This picture is of where the tab should be.

https://cimg2.ibsrv.net/gimg/www.rx8...f79af660b2.jpg

I have been meaning to do a DIY and take pictures, but they keep breaking at the worst times. The pictures below show what it looks like fixed. What broke is the part that looks like epoxy resin.

Process:
Look at how the arm with the spring on it comes in and out, It rides in a slot, and only goes in one way. Look at the little taps that stick out, you will figure it out.

Cut a thin strip of metal for the spring to rest against. Can really be anything. Spend time bending it to follow the curve, like mine is in the picture. Do not worry, there is a lot of plastic still there, the only part that broke off is the tip. It looks darker in the picture. The only part you have to make up is the very tip. I curved mine up on the end, like in the picture. Do not make too big a tab on the end, or it will be hard to reassemble.

Cut a small notch in the plastic for the metal end (not the one the spring touches) to sit into. You need to make sure that handle will go back in the door. It needs all the space around the opening to fit back in. I do not have a picture of this. But, if the handle will not go back in the door, that is the problem. This one barely fit.

Then, use masking tape to hold the metal in place, protect the channel from filling with resin, and protect the little hole from filling up. Basically you are making a mold for the missing pieces, and filling in a few of the voids on the handle for a stronger product.

Did I mention that the repair is fiddly. Take your time. Once you think all of the parts are in good shape, mix a little resin (not the tube kind, unless JB weld (not the JB quick)). You need something hard and the tube epoxy does not get hard enough. Use the resin to fill all the voids, and let it cure overnight, or at least several hours, no matter what the bottle says.

Then. Pull off the tape, clean out the resin that got where it should not be, and re-assemble. If it broke all the way, then you have to figure out how it goes back together. I hope the picture will help. The spring goes on your new perch first. The last thing you do is put the handle, paint side down, on a soft surface. Then use the end of a small screwdriver the push the other end of the spring in, and behind the post. This is not fiddly, is PITA. Just keep trying.

If the spring slips off your perch, look at bending the tip of the spring a bit or expanding out the spring to keep pressure in the right direction. The spring will try to slide off the metal. From the factory it digs into the plastic and does not slip. That is why it eventually tears through it. Since you are reading all of this through before doing it, think of this problem when you bend your metal. Maybe there is a way to get a lip to hold the spring. I am not sure. share if you come up with an addition.

Suggested improvements for the next time I do this. Use hot glue to hold the pieces together instead of masking tape. A lot easier, I think. Also, I plan on testing the new UV cure adhesives. If they get hard enough, they will be much nicer than resin to work with, and a lot faster.

This is fiddly, but not hard. All I can suggest is taking your time. If the next door goes on my car, I will try to get better pictures and see if I can do a DIY. But, you cannot wait that long.


https://cimg3.ibsrv.net/gimg/www.rx8...d77d302e53.jpg


https://cimg6.ibsrv.net/gimg/www.rx8...dc9f1459c5.jpg