Topic: 68 inside door handle will not "clock" correctly

[Murf]

In an attempt to rectify incorrect items found at Columbus GN, I am stuck on trying to get the inside door handles to "clock correctly.  Yes, the handle is a reproduction and the "splined stem" is a Ford issue.  No matter how the handle is installed it is about 1/2 spline off of where it is supposed to be.  Right and left side both are off.  Certainly the repro door handle is splined incorrectly since the originals fit OK, but has anyone come up with a way to get this correctly clocked without finding two NOS handles?  I am wondering if the reproduction "stems" are also !/2 spline off and therefore would make the repro handles correct?  Stuff like this drives me nuts!  So if any of you have faced this issue and have solved the problem please help.  Maybe there is something I am overlooking?  Thanks in advance.

[J_Speegle]

Just a "from the hip" thought (never done it)

Can the handle mechanism be rotated that couple of degrees where it attaches to the door - and everything still work?

Might be worth a try

[67gtasanjose]

...another "thought" not tried...change out the splined shaft with a "same supplier" part, meaning if somebody such as Scott Drake sells BOTH items for each side, buy all 4 pieces and if it doesn't work out correctly, send all 4 parts back with a complaint of fitment. As long as we don't cry loud enough on these junk parts, we will keep getting the same junk parts.

Again,...Just a thought.

[WT8095]

Going off of memory here, but I think the rotational stop points are determined by the latch, not the handle relay. In other words, I don't recall any hard stops inside the relay unit. So, in theory, a slightly longer or shorter actuator rod connecting the relay to the latch would cause the relay bell crank, and thus the handle, to stop at a different angle. I would experiment with a junk actuator rod - try bending it a bit to shorten it and get the splines where you need them.

[Murf]

The rotational stop is a slot in the door shell, but it can only let the handle go so far.   Typically, before the slot is used in total the length of the rod stops anymore turning of the splined stem.  There is just not enough "slop" in the system to get these handles the  way they need to be.  I fooled with these when assembling the doors and no matter how I stacked the parts the handle either drooped or was
uphill".  The advice about using a repro stem is good and I have hope that someone will have done that and chime in.  I suspect that others have had this problem.  Thanks for the suggestions.  I cringe when using a reproduction part because of issues such as this and wonder how in the world others have overcome the shortcomings of some parts. 

[ruppstang]

As Jeff alluded to the easiest fix is to file the mounting holes to allow it to turn a degree or so.
Those darn picky judges!    

[krelboyne]

That is a design flaw with the reproduction folding door handles. The splines are clocked wrong in the castings.

[TLea]

That is a design flaw with the reproduction folding door handles. The splines are clocked wrong in the castings.

+1. All the repo handles do this. Only fix is NOS or take a dremel and add 1/4 to slots to rotate further

[Murf]

Thanks, everyone.  After the Thanksgiving holiday this will be Job #1.  Will post the results. 

[Murf]

Fixed!   A Dremal and a small Ball cutting tool took care of things.  Needed about 3/16 inch hogged out to make things right.  A pain to go back and repair and makes me mad at myself for not catching the problem upon assembly.  All is well now and thanks for your help. It appears this has been an ongoing problem and that others have contacted Scott Drake about the issue but obviously no fix from their end. 

[67gtasanjose]

... Needed about 3/16 inch hogged out to make things right. 

"What" gets hogged out? The slots in the door I presume?

[Murf]

Yes, the holes that were in the door (3 in each door)  are now slotted.  It does not take too much but each hole requires some modification.