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Premium Member
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Discussion Starter #1
Some of us are still doing new DSM stuff!

2G Billet aluminum door handles are finally being made!
 

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Hmmm, very interesting. Has to be better that the piss-poor brittle OEM design on our 2G cars! Hate to try and open a door fitted with these on a hot summer day in Phoenix, but cars used to have door handles made out of cast metal years ago.

What alloy of aluminum are you milling these handles from? 7075 would be the best candidate, as it is far stronger than 2024 or 6061-6063 (I was a mechanical engineer before retiring in 2017). Unfortunately, it is also tougher to machine and more expensive than the more common alloys. Raw 2024, while it forms a protective oxide layer like all aluminum alloys, becomes yellowish over time and the oxide layer is not very durable. For appearance, 6000 and 7000 series alloys are good for anodizing, should someone want the handle to match the paint color of the car, or just to maintain a shiny appearance with clear anodization. Unanodized aluminum exposed to the elements outdoors will eventually turn a mottled grey color, like an unpainted aluminum screen door.

https://www.clintonaluminum.com/the-best-aluminum-for-anodizing/
 

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That's pretty cool! I feel like there has been chatter about them for a loooong time. I don't think I've ever seen a completed set. I never had a 2g so I never followed closely, but it's still cool to see new things. Plus I love me some billet!
 

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Premium Member
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Discussion Starter #4
Hmmm, very interesting. Has to be better that the piss-poor brittle OEM design on our 2G cars! Hate to try and open a door fitted with these on a hot summer day in Phoenix, but cars used to have door handles made out of cast metal years ago.

What alloy of aluminum are you milling these handles from? 7075 would be the best candidate, as it is far stronger than 2024 or 6061-6063 (I was a mechanical engineer before retiring in 2017). Unfortunately, it is also tougher to machine and more expensive than the more common alloys. Raw 2024, while it forms a protective oxide layer like all aluminum alloys, becomes yellowish over time and the oxide layer is not very durable. For appearance, 6000 and 7000 series alloys are good for anodizing, should someone want the handle to match the paint color of the car, or just to maintain a shiny appearance with clear anodization. Unanodized aluminum exposed to the elements outdoors will eventually turn a mottled grey color, like an unpainted aluminum screen door.

https://www.clintonaluminum.com/the-best-aluminum-for-anodizing/
I used 6061 to keep the price in check. I offer clear and black anodizing.
Polishing the 6061 and works very well but has to be done every couple of years to maintain the shine. I recommend that anyone who gets the raw finish to make sure that they prime and paint match to keep a good finish.
 

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Discussion Starter #5
Here's the real deal! :D
That's pretty cool! I feel like there has been chatter about them for a loooong time. I don't think I've ever seen a completed set. I never had a 2g so I never followed closely, but it's still cool to see new things. Plus I love me some billet!
 

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17,452 Posts
Very very cool....but late. haha
It does make me happy that people still care about these cars though.
 
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