This section is about how I made the inside door handles and window cranks. I liked the simple design of the door handles I had but the window cranks didn't seem to fit with them I don't know if they were stock or not but I don't believe so as they were chromed. Stock door handles were OD green and I'd assume the window cranks should have been the same.
Album by Kevin Foust. Photos by Kevin Foust. 1 - 11 of 11 Total. 1516 Visits.
1 I started on the door handles first. I got a 1/2" thick stainless plate and plasma cut the shape out, I then started smoothing them out with the 9 inch angle grinder with both of the clamp together to keep them the same.
2 I then moved to a belt sander that I mount upside down in the same vise and lock the power on. This gives me a poor mans sanding table. I kept the handles together for this as well and once done I took them apart as shown here. Now they have a nice, even swoop.
3 For the mount side I got a length of round and started the pocket. A mill would make this easier but I drilled the corners and center. I then used a die grinder to make the sides to match the flats of the door latch attachment point.
4 I then ground the square out and cross drilled for the retaining pin. I also drilled for the handle attachment points.
5 I then sanded it out and polished everything. Cut it off and drilled and blind hole tapped the handles.
6 The 2 new ones with the original below.
7 Used countersunk allen head screws to hold them on.
8 Drew up a pattern that was similar in design for the window cranks. I did the same process as before and here they are after rough sanding. I did some hand filing to give it more detail around the knob mounts.
9 Bought some new knobs that fit with the design and made up some contour pieces. Drilled and tapped the holes. Sanded out and polished everything.
10 The completed cranks and I like how these turned out.
11 Here you can see how they kinda fit together by design. Piece by piece I'm getting there.
