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Car Forum / Ford / Ford Trucks / March 2008

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A TRICK!  Broken Expedition rear lift gate handle

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Steve Hartman - 05 Mar 2008 04:37 GMT
OK, so I broke that sucker right in half!  And good ol' FORD...it wants $158
for a new one.
First thing to know is...it's really easily to get out and off.

I took some plaster of paris and made a mold of the good half, then flipped
it around and used the good half to make the other side of the casting as
well.  To halves equal one whole - right?

OK, then I layed some Glad wrap in the bottom.  Next, I drill a couple of
holes into the center of the old handle and stuck in a couple of 6 penny
finish nails for support for the missing side.  Finally I stuck the broken
handle into the mold and raised it up abut an 1/8" above the bottom.  And
finally I filled the mold full of casting resin.  And yes, you want to
completely cover the back side as well.  So I guess we should say - YOU
IMMERSE THE HANDLE. LOL!

After 4 hours I pulled it out and started sanding.  Aside from the painted
"Dummy" signage on the original handle the new one looks jes' like the real
thing....and I have no worries about it ever breaking...  Total cost about
$21.
DanKMTB@gmail.com - 05 Mar 2008 15:41 GMT
> OK, so I broke that sucker right in half!  And good ol' FORD...it wants $158
> for a new one.
[quoted text clipped - 16 lines]
> thing....and I have no worries about it ever breaking...  Total cost about
> $21.

Nice work.
 
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