1991 Acura NSX Long Term Road Test

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1991 Acura NSX: Fixing the Door

January 02, 2012

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The replacement billet door lever from ScienceofSpeed.com came in last week, so I decided to fix it this weekend. All in all, it was an easy fix; maybe a four on a difficulty scale of ten. It wasn't completely without some frustration, as you'd expect, but there's certainly a feeling of satisfaction that comes with fixing something yourself.

The first step is to remove the door panel that slides into the handle and lever pocket. I used a plastic putty knife the lift the edge, then pulled it out with some pliers wrapped in a small towel (so as not to tear the leather).

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It took some effort to get the panel off, but once removed, the door mechanism was now visible.

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Six screws held the pocket in place. I removed them and placed them in the same orientation off to the side, ensuring the screws go back in their original locations.

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Here's the underside of the pocket. Now you can see the part that broke. Pretty cheap metal, I'd say, just a step above plastic. See the black dot right next to the fracture? That's a sticker that covers some very small screws.

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These small screws gave me the most problems. I thought I was sunk, since I didn't think I had a screwdriver small enough for the job. Then I came across a miniature screwdriver set I bought a few years ago. Let's hear it for having the right tool for the job!

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The first screw needed a lot of effort to remove. When I finally got it out, I found out why.

There was a lot of red thread lock on it. The second screw wouldn't budge, and I ended up stripping the head. A few choice expletives later, I came up with a fix.

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That metal was pretty cheap, so I pried it up with a flat screwdriver and just snapped that sucker right at the hole.

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Next, I popped the C-clamp that was holding in the hinge pin. I dropped in the new billet aluminum piece and reassembled the whole mechanism.

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While I was re-installing the leather door panel, the pliers slipped and put a scrape on the inside of the door handle. I'm pretty sure my neighbors think I have Tourette's Syndrome now.

NSX_Doorfix_11.jpg 

Thankfully, last week I made a model of one of my personal cars and had a tiny bottle of Testors flat back paint. A little dab later, it was all fixed.

That's it. The door works just fine now. There's a little bit of binding halfway through the stroke, but nothing to worry about.

Mark Takahashi, Automotive Editor

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