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DB7 Door handle repair

15 Jan 2023 10:20 AM | Anonymous member (Administrator)


Right from the very start the DB7 door handle has been fragile.  It was a Mazda part, and it is not being used as it was designed for. The way it is fitted on the DB7 means that the opening mechanical stop is the lever arm, not the stops designed into the handle.  This means that if the handle is given a good tug, it will break, and it will also break under fatigue. This even happened to the prototype

If the lever arm does break off, there are two, so you can dismantle the other door and swap them over.  You can only do this once.

New door handle are £180 and don’t fix the problem.  It will still break.

Using this 3D printed part you can remove the  handle and glue this new part in place to repair the lever arm.  File down the plastic so that the new part fits in place and glue in using superglue. Roughen up the chrome surfaces before glueing. It is substantially stronger than the original.

You can print the part from the STL file attached to this post.  If you need the other side, then mirror the part in the print software.

Screenshot 2022-09-09 at 11.13.09.png
Also included is a part to repair the upright.  The one in the photo was taken off a scrap car. It is the first time I have seen a broken upright.

Screenshot 2022-09-09 at 11.13.52.png

EdAdded Jan 2024

The design of the part has been upgraded to include a  'jig' to make filing down the plastic more accurate, and a small piece to make pushing out the nylon arm holder much easier.


If you are printing this part use Polycarbonate or Nylon filament for the higher temperature range.  When in the sun the inside of the door could exceed the 60C  glass temperature of the standard PLA filament. (It will become very bendy).



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