95REGF150
10+ Year Contributor
- 447
- 242
- Mar 7, 2012
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Elk Grove,
California
Not sure I was clear. I meant only the currently plastic door handle part could be made as three pieces. The two arms could for example be easily cnc cut, with the now smaller and more simply shaped handle portion missing the arms could be more easily cast, and then the three parts tig welded in a simple jig.
A cast Al to cnc Al welded handle would still be much much stronger than the oem plastic handle. It's just a cost-saving measure (which doesn't always save cost depending on the vendor) that we use in industry.
You might even be able to get away with a bolted joint and some small dowel pins if you didn't mind looking at the heads of the bolts from the outside. But I think Bobby's single piece casting will be cheaper than multiple pieces if there is enough quantity there.