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      08-14-2017, 11:21 AM   #1
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Replace Peeling Driver Door Pull

Background:
Everyone with e9x series car understands that over time, the interior soft touch coating is fragile and prone to peeling. Most live with the defect as the available fixes are costly or substandard.

Based on my research, fixes are limited to (1) complete door card replacement, (2) Plastic Dip respray and (3) peel-off completely and live with the imperfection.

This is a definitive DIY to replace the soft touch plastic door pull without needing to scrap the entire door card and integrated upholstery.

The steps below require doorcard removal. I used this diy. http://www.billswebspace.com/e92DoorPanelRemoval.htm


I recently acquired M3 door cards and noted peeling in the driver pull handle (Fig 1). A new OEM replacement door card is $1100 and many used panels are dented or damaged and not suitable for use. Since I had my original card with an undamaged interior door handle (Fig 2), I set to the challenge of swapping the handle. Upon inspection, I noted 2 heat welds bonding the hard plastic pull to the door card. (Fig 3).
I drilled these welds using progressively larger bits. It is important to take care in drilling just as much material is needed to break the weld. Drilling too deep could puncture the handle making it unusable. Excess weld material was cleaned up using a sharp chisel. Resulting effect (fig 4).

I inserted a scraper into the gap and with some gentle print the handle was free (fig 5).

Repeat the above steps for the donor panel.

Some light edge cleanup and some exterior mounting tape (I considered JB weld but didn't have any on hand) and the undamaged handle fit the m3 armrest like a glove (fig 6).

I then went about replacing the door card by reversing the steps in the above diy.

Sit back and enjoy the result (fig 7).

Pics to follow.
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      08-16-2017, 12:51 PM   #2
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I bought a new handle, which was not too expensive. I didn't have a way of melting the mounting posts, so I cut them off flush with the back of the door card, drilled holes in the mounting posts, and installed sheet metal screws and big washers. Easy to do, and looks much better.
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      08-27-2017, 11:53 AM   #3
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Quote:
Originally Posted by m_thompson View Post
I bought a new handle, which was not too expensive. I didn't have a way of melting the mounting posts, so I cut them off flush with the back of the door card, drilled holes in the mounting posts, and installed sheet metal screws and big washers. Easy to do, and looks much better.

Is there any chance that you have details as to how you trimmed off the heat weld and how you used the sheet metal screw to attach new door pull. I've got this same issue with my 2008, which I'd like to revive just a bit..
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      08-28-2017, 05:51 PM   #4
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Quote:
Originally Posted by jwebb335xi View Post
Is there any chance that you have details as to how you trimmed off the heat weld and how you used the sheet metal screw to attach new door pull. I've got this same issue with my 2008, which I'd like to revive just a bit..
I'll try to post pics tonight.
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      08-29-2017, 12:10 AM   #5
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Quote:
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Quote:
Originally Posted by jwebb335xi View Post
Is there any chance that you have details as to how you trimmed off the heat weld and how you used the sheet metal screw to attach new door pull. I've got this same issue with my 2008, which I'd like to revive just a bit..
I'll try to post pics tonight.
No rush! Thanks for your response.

I'm replacing steering wheel trim and driver door arm rest. I'm also watching the news and feel blessed that my family is NOT being flooded out of our home!!
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