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> rebuild your door stay, a pictorial guide
davesprinkle
post Mar 12 2006, 01:18 PM
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What you'll need:

1. One worn door stay mechanism. If you own a 914, you probably have two.
2. A bench vise, bolted to a bench.
3. Replacement door stay and replacement rollers. (Here's the shameless plug -- I have these available for sale.)
4. Blade screwdriver for removing and replacing springs and clips.
5. Wheel bearing grease.
6. Eye protection.
7. 20 minutes.

OK, the first step is to remove your door stay mechanism from the door. I won't cover this step here. It's pretty simple, but if necessary, refer to this article on the Pelican Parts website. Install the mechanism in the vise, clamping on the door stay itself.


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davesprinkle
post Mar 12 2006, 01:22 PM
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The second step is to remove the springs from the mechanism. I don't think I need to remind you to wear eye protection for this step. Be sure to watch carefully where the spring goes when it leaps across the room.


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davesprinkle
post Mar 12 2006, 01:25 PM
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Here is a picture of the mechanism with the springs removed, still clamped in the vise. Note that the metal roller in the mechanism runs against the "bumpy" side of the door stay. The plastic roller runs against the smooth side of the door stay.


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davesprinkle
post Mar 12 2006, 01:28 PM
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Here is a picture of the old door stay. Compare its condition with that of the new stay in the plastic bag. Although the old stay is noticeably worn, it is not as bad as some that I've seen. In many cases, the bumps are completely worn away.


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davesprinkle
post Mar 12 2006, 01:32 PM
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Remove the e-clips holding the roller shafts in place. Again, be sure to wear your eye protection for this part. Don't lose these!



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davesprinkle
post Mar 12 2006, 01:35 PM
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Here is the plastic roller. This roller exhibits the typical wear pattern; that is, it's completely worn through. Although it isn't shown in this picture, the aluminum roller had a severe flat spot, which again is the typical wear pattern.



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davesprinkle
post Mar 12 2006, 01:39 PM
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Here is a picture of the dissassembled mechanism, with the parts roughly arranged in the order in which they'll go back together. Note the new rollers.



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davesprinkle
post Mar 12 2006, 01:43 PM
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Apply a light coating of wheel bearing grease to the roller pins. Do not lubricate the exterior of the roller. You want grease on the inside of the roller, not the outside. (Think of the roller as if it were a tire -- you don't want grease on the rubber tread, do you?)


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davesprinkle
post Mar 12 2006, 01:45 PM
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Here is a picture of the new rollers installed in the mechanism.



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davesprinkle
post Mar 12 2006, 01:50 PM
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Here is a picture of the new door stay in the mechanism. Note its orientation -- the side of the stay with the bumps runs against the brass roller.


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davesprinkle
post Mar 12 2006, 01:52 PM
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Put the mechanism back in the vise, clamping on the stay.



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davesprinkle
post Mar 12 2006, 01:58 PM
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Reinstalling the springs can be a real hassle. I use a blade screwdriver with a round shank (Craftsman). Be careful and wear your safety glasses!



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davesprinkle
post Mar 12 2006, 02:00 PM
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Finished! Isn't it lovely?



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Air_Cooled_Nut
post Mar 12 2006, 02:05 PM
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What side of the car are you working on in this pictorial?

Nice work!
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davesprinkle
post Mar 12 2006, 02:09 PM
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QUOTE
What side of the car are you working on in this pictorial?

Nice work!


Thanks for the kind words. In answer to your question, both mechanisms are identical; one is just installed upside down from the other.
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turbo914v8
post Mar 12 2006, 02:10 PM
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I will take a set how much?
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davesprinkle
post Mar 12 2006, 02:17 PM
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I will take a set how much?


$43.27 delivered to your door. Includes one plastic roller, one brass roller, and one door stay. Here's a link to the products forum.
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olav
post Mar 12 2006, 03:33 PM
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Check is in the mail. (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)
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davesprinkle
post Mar 12 2006, 05:50 PM
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QUOTE
Are the springs available somewhere?


Sorry, I'm not aware of a replacement source for the springs.
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michel richard
post Mar 12 2006, 05:53 PM
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This is cool
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