2g Aluminum handles

[b00st3d]

You can see the variation here. There are 3 different thicknesses of levers.

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[b00st3d]

The ones I seem making will have an additional tab like this. It could also be solved by drilling a small hole and running a bolt through the lever and handle arm to fix them together.

With the billet handles this should be no problem add they have the relief for the lever just like factory. I will also have the upgraded levers available.

 

[Tiki2777]

The ones I seem making will have an additional tab like this. It could also be solved by drilling a small hole and running a bolt through the lever and handle arm to fix them together.

With the billet handles this should be no problem add they have the relief for the lever just like factory. I will also have the upgraded levers available.

That's awesome Tony, standing behind your product is commendable, have you yourself ran into this issue on your personal vehicle?

 

[EC17PSE]

The aftermarket ones vary by set, even between sides I have seen variation.
The ones I am making are 14g stainless and have a tab that will fold around the arm. The next weak link will be the plastic from the bezel(not anything I can do about the people that break those..

i would consider going even thicker! i forget the oen size and can check tomorrow but im pretty sure its near 2.5mm thick. so 14G wont cut it even if its stainless, thats my opinion at least anyway,

 

[b00st3d]

That's awesome Tony, standing behind your product is commendable, have you yourself ran into this issue on your personal vehicle?

I have had 1 other person experience this same problem. I haven't had any other reported failures.

 

[b00st3d]

i would consider going even thicker! i forget the oen size and can check tomorrow but im pretty sure its near 2.5mm thick. so 14G wont cut it even if its stainless, thats my opinion at least anyway,

The factory ones are 1.5mm thick not 2.5. These are thicker(14G is 1.95mm) than the factory and stainless rather than regular steel. This is stronger than the factory piece. and way better than the normal aftermarket ones.

 

[b00st3d]

The problem with going thicker than 14G is that the design of the handle will need to be changed as there is not room for a thicker lever without causing it to bind.
If this remains a problem with the new stainless lever, the next thing will be to go to 12G and redisgn the handle arms to have a large enough relief for the thicker lever.

 

[EC17PSE]

I measured mine today, (oem) and its 2mm thick, the spring is also 2mm thick and thats oart of the problem, its a tad too stiff for a handle, these are new out the box ffrom nov 2018, if yours are 1.5 not sure why that is, i will confirm my old handle aswel

 

[b00st3d]

I measured mine today, (oem) and its 2mm thick, the spring is also 2mm thick and thats oart of the problem, its a tad too stiff for a handle, these are new out the box ffrom nov 2018, if yours are 1.5 not sure why that is, i will confirm my old handle aswel

Pulled it off a 97 Gst factory handle. So unless mitsu made changes that's definitely an oddity. I am using digital calipers. The after market ones measure 1.38mm (which is very close to 17G measurements)
The OEM one I have here measures 1.54mm. 16G is 1.5875mm
The only other oem handle I have is still on the car.
I am using 14G stainless which 1.9843mm. The strength difference between mild steel and stainless even if I were to use 16G should be more than enough to eliminate the problem.

 

[b00st3d]

I am using 14G stainless which 1.9843mm. The strength difference between mild steel and stainless even if I were to use 16G should be more than enough to eliminate the problem.

Add the tab that will wrap around the arm to that strength and the next weak link is the bezel.
The problem with fixing one thing is it will now lead to a new problem and it will be an endless tail chasing.
The aluminum handle won't break -> this leads to the lever bending and still making the door not function.
Once the lever is strengthened, then the bezel will break and we will have to devise a fix for that.
Once the bezel is strengthened, the rod will bend then we will have to sort a fix for that.

 

[EC17PSE]

you ideally dont need to touch the arm, i have never bent one and never seen anyone until now mention it being an issue, the spring is just too stiff for the setup so if that went down in size it would soften the pull and be alot nicer to the plastic upright where the bolt goes through,

as for mitsu changing im not sure, i can let you know tomorrow what my oem handle had from the factory as its at work currently if that is the same then they never changed them but i will confirm all this tomorrow

 

[b00st3d]

you ideally dont need to touch the arm, i have never bent one and never seen anyone until now mention it being an issue, the spring is just too stiff for the setup so if that went down in size it would soften the pull and be alot nicer to the plastic upright where the bolt goes through,

as for mitsu changing im not sure, i can let you know tomorrow what my oem handle had from the factory as its at work currently if that is the same then they never changed them but i will confirm all this tomorrow

Unfortunately that isn't an option given that 75% of the people who order handles want them loaded into bezels. Since I don't have their OEM ones the only option is aftermarket.

 

[b00st3d]

These lever are more expensive that I thought they would be to manufacture!
Material cost + waterjet cost + break cost(bending) + the retainer clips that I still need to source.

It's looking like this will end up being about $40 for a set.

 

[EC17PSE]

Unfortunately that isn't an option given that 75% of the people who order handles want them loaded into bezels. Since I don't have their OEM ones the only option is aftermarket.

Arh that is very true in deed! Then they take that risk of a weaker bracket thats out of your control,

On a side note i just got into work and measured the oem one that came on the car from the factory and its still 2mm! 1.97mm to be exact, this one is zinc plated clear (silver in color) the one i got end of 2018 was zinc plated color (gold ish color)

So from this im saying they stuck with 2mm from the get go so as long as you stay around there it should be ok,

 

[b00st3d]

Here's the new stainless lever.

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[ThunderChild]

Interesting, I'm wondering where the binding is coming from? Seems like the spring would have to be crazy heavy for the bracket to bend, or there's an obstruction somewhere (like the common "frozen door" in northern regions) increasing load. I'll have to pull my Spyder door panels when I can and do some more inspecting to see if I can find any spots that look susceptible to hangups.

It's either that or people are gorilla-reefing the handles, which can't be helped.

 

[b00st3d]

The 2 reported failures were from different parts of the country so I can't really pinpoint the problem. But for anyone that has the problem, I now have a fix.

 

[b00st3d]

Here it is on a handle. Definitely beefy.

 

[lowblue64]

Just broke a handle again today....do you have any sets ready to go or need I get on a list?

 

[chrislxd]

Is this still available? I would like to get a set. Thanks in advance

 

[randomquickness]

wish I knew about these before I installed the amazon handles. Oh well, I can confidently say they will break and I'll put yours on my to do list. Love seeing grass roots fixes for a common problem like this!

 

[Dusty Landrum]

Order placed! I am not exactly sure where you are now on the production process. Was a long thread... but are you shipping them with the housing and everything now? And is painted an option now as well or just primer?

 

[b00st3d]

I don't make the welded handles any more. I have the Billet aluminum handles from my other post.