1. Once the donor doors are...
1.Once the donor doors are apart, mark the area to be removed, and make sure you cut it oversized so it can be trimmed to fit later.
2. There are a few ways to...
2.There are a few ways to cut the sheetmetal. John opted to use a cut-off wheel. Whatever you use to cut the piece out, make sure you don't overheat the area and cause it to warp.
3. Make a template of your...
3.Make a template of your new handle skin and transfer it to the stock door to get a precise cut area. This is a critical time to get your donor skin level and straight, because who wants a crooked handle? The next images will show how John got his lined up.
4. Find the new handle centerline...
4.Find the new handle centerline and reference with a level centerline on the door skin. John used the door edge and the beltline for his reference points. Measure three times and cut once. At this point, there is no turning back and you could easily do irreversible damage to your truck, so take your time. Make sure to transfer these exact measurements to the opposite door, also.
5. Test-fit your new piece,...
5.Test-fit your new piece, and keep grinding until the piece fits nice and tight. John recommends butt-welding when doing a swap like this. This type of welding leaves the new grafted panel exactly level with the surrounding skin. Lap-welding would leave the donor handle skin too far behind the stock skin and cause the handle to have a recessed look.
6. Grind the edges to be welded...
6.Grind the edges to be welded to bare metal around your donor handle skin and stock skin. When welding, skip from the top of your patch to the bottom, making only short-burst spot-welds. Do not weld the entire patch at one time. This will warp the hell out of your door. You may even want to skip from the driver side to the passenger side, letting your welds get cool to the touch. Do not force cool with shop air or quench with a wet rag. This can also cause your panel to warp. Just take your time and be patient. This is not a mod that can be completed in one afternoon. Set aside a weekend.
7. John uses a digital setting...
7.John uses a digital setting Millermatic Model 251 220 welder using 0.035 wire, 75/25 mix argon/CO2 shielding gas, 14.6 volts, and 160 wire speed. Settings will vary, depending on your welder and the thickness of the metal being welded. He does not recommend using a gasless welder for this procedure.
8. Follow with your favorite...
8.Follow with your favorite autobody filler. Sand smooth using an inline air sander, starting with 36-grit paper, and after that, step down to 80-grit. Then, hand-block using 80-grit, then 180-grit. John recommends using 3M products. Scuff the surrounding areas and prime using your favorite finish primer. CCC uses Transtar 4/1 High Build Gray Primer. Do not forget to cover the bare welds on the inside of the door skin with either weld-through primer or undercoating to prevent rust.
9. John spread the mud and...
9.John spread the mud and blocked it smooth, before coating the area in primer. Once the primer cured, there were a few more rounds of blocking before the paint was laid down.
10. Here is the handle area,...
10.Here is the handle area, once the truck was finished, and as you can see, it really looks nice. The quality of the handle is good because it is an OEM item, and since the Malibu and S-10 handle share the same functionality, the lock rod hooked up with only one minor bend.
SPORT TRUCKTECH TIP
JUST A REMINDER
Don't forget to remove door glass from the inside of the door, because it will pit from welding and grinding. Always remove any trim or hardware from inside the door that may get damaged during the welding procedure. Cover all exterior glass and paint. John at Clean Cut Creations uses 3M Welding and Spark Paper, PN 05916. He says, "The product is expensive, but it's cheaper than buying new glass." Do not use standard masking paper, cardboard, or your grandma's old blanket because these things will catch on fire as you are working. If you are working with the truck door open for any reason, cover all interior areas.
THE FINAL WORD
This installation will be different on each vehicle, depending on what donor handle is used. But, the most important thing to remember is to completely bolt in and mock up the new handle, and fab the lock rod and handle linkage with the glass and gasket installed to check for clearance. If you have an S-10, you might want to consider the Malibu as a perfect donor, but again the options are only limited to your imagination.