We have come up with a way to rebuild the door latches/mechanisms for shaved handles. This also helps minimize the slack that is in the star.
The first step is to grind down the rivets and knock them out.
Grind out the one just below the star. Also grind out the one on the right side in this picture.
Punch out the rivets and this is what you are left with.
Next you want to cut the tab off of the end.
As well as cutting out this tab.
Once thats done, grind down the edges of the star on the back side. enough to knock it out. I like to leave a nugget of metal in the middle for later.
These are the pieces that are left when you cut everything and knock out the star.
Next you want to cut down the push release. * BE SURE NOT TO CUT THE POINTED EDGE THATS UNDERNEATH THE BOTTOM PIECE THAT YOU CUT OFF! YOU NEED THAT!!!*
Then you want to weld tab number 1 to the push linkage. getting it as close to the side as possible without touching it.
Weld tab number 2 down towards the bottom of the mechanism. (yeah, I know my welding sucks)
Now you want to weld a very small amount onto the point that I told you not to cut off earlier. This helps with the movement of the star.
The brass fitting that holds the star in can either be replaced with a new piece that needs to be cut down, or you can just clean it up and put it back in. We cut new pieces and put them in. I dont remember exactly what size it was, but he picked it up from ACE I think. There is also a very small plastic white washer that he used to space the star on the outside. Kind of hard to explain cuz I dont have photos of it. I didnt have an extra one when I did this rebuild. Im not using this one in my car. Anywho, here is that brass fitting.
Now reassemble everything. Remember to use a lot of grease when reassembling. It really makes everything smooth.
