Rides by Kam Custom Car Building Tips: Flush Fit Handles

Rob Zahabi from Rides by Kam shows how to install flush door handles.
Step 1: Get down to bare metal (01:08)
After you’ve taken all the parts out of the door, get it back down to bare steel so it’s ready for welding. We use the 3M™ Orbital Sander with 80-grit 3M™ Cubitron™ II sandpaper and 3M™ Welding and Spark Deflection Paper to protect the area you’re not working on. Scotch® 233+ Performance Green Masking Tape is nice and thick to hold everything down.
Step 2: Make up and weld in the template (01:41)
Make up the template to fill in the old door handle or the factory door handle hull. Make sure it’s contoured to the body line before you weld it in. Treat it like you're actually going to finish it flush fit with no door handle so you get the whole area perfectly straight and flat.
Step 3: Figure out the position (02:38)
Mark out a template for where to position the new flush fit door handle. Consider how it will line up with the striker inside the end of the door. You also want the handle to be pretty close to the factory position so it doesn't look odd.
Step 4: Cut the hole and install the handle (03:06)
Use your template to cut the hole. Take the center section out and insert the handle from the back, then weld the back section in place and fine-tune it from there. We’ll show you how to do the rust treatment and edge primer in another episode.
Important note:
There are of course many factors and variables that can affect an individual repair, so the technician and repair facility need to evaluate each specific application and repair process, including relevant vehicle, part and OEM guidelines, and determine what is appropriate for that repair.
Products used in this video:
3M™ Orbital Sander Original
www.3m.com/3M/...
3M™ Cubitron™ II Hookit™ Clean Sanding Abrasive Disc, 31371, 80+ grade
www.3m.com/3M/...
3M™ Welding and Spark Deflection Paper 05916
www.3m.com/3M/...
Scotch® Performance Green Masking Tape 233+
www.3m.com/3M/...
For more advanced tutorials, check out 3M Collision Repair Academy
www.3m.com/3M/...
You’ll find courses that will expand your knowledge, deliver practical procedures that you can use right away, and, in many cases, earn you I-CAR credits.
Website: 3MCollision.com
Instagram: 3MCollision
Facebook: 3MCollision
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[@mangoco10]

Awesome. Fantastic explanation and vid, thanks.

[@LT4Nova]

By far the best initial metal work I've seen for these handles. What pad did you use for the sanding before primer?

[@stevejanka361]

Good evening, beautiful metal work. That metal finish looks great. What was that clever magnet fixture you used to hold the the filler piece in place when you spot welded it in. Thanks for another informative video. I always learn something new from your info. Thanks and take care.

[@Thatguy-dk8zm]

Awesome love your work

[@craigleveridge-tr1rw]

Does the change of direction you mentioned allow the handles to be used on latches that need a verticle movement?

[@dionisharvey1046]

Where are you all located?

[@williamfeliciano7559]

What wire size are you using on your mig work.

[@M.Dredemtion]

Very cool but this means U CANT LOCK YOUR DOOR SO BE HAPPY GETTING ROBBED

[@stuartbrown881]

Remote central locking soon solves that issue

[@Heartlandrods]

Power locks, problem solved.

[@chickenbonelives]

Don't keep anything valuable in your car lol