How to Shave Door Handles

Nice, clean lines and a smooth body are what you will get with shaved door handles. This extreme-looking modification is not as difficult as it may seem. A little hard work and some patience will have your car or truck looking sleek and customized. There are many kits on the market that make this modification possible for all car enthusiasts.

Things You'll Need

• Shaved door kit
• Body filler putty
• Sand paper
• Die grinder
• Welder
• Acid-etch primer
• Sandable primer
• Paint
• Adhesion promoter
• Assorted hand tools

Instructions

1. Remove the interior trim panel and place it in a safe place.

2. Roll down the window and completely remove the bolts that are holding the glass. Be very careful.

3. Carefully remove the trim pieces from the top of the door, then remove the mirror. Pull the window glass through the top of the door.

4. Remove all plastic parts and/or insulation from the inside of the door. Then remove the door handle.

5. Place the metal filler plate, provided in the kit, into the correct spot to test for fit.

6. Strip the work area down to bare metal and tack-weld the filler plate into place.

7. Continue to tack-weld all the way around the area. Cool with a wet cloth as you go, and work slowly.

8. Grind down the high spots so that everything is flush. Scuff the area with sandpaper and apply filler putty.

9. Sand the filler smooth with 400-grit sandpaper. If you run your hands over the spot, you will be able to feel waves.

10. Apply acid-etch primer to the inside and outside of the door. Let it dry. Then apply four to five coats of sandable primer to the outside only.

11. Sand the primer smooth using 500 to 800 grit sandpaper.

12. Apply the adhesion promoter, then paint the door panel.

13. Install the door-opening mechanism and run the wires to the desired position for your door switch.

14. Working backwards from where you started, reinstall all door parts. Test the operation of everything.

15. Now its time to show off your work.

Tips & Warnings

• Label the parts you take off your car. Draw a diagram of your door if you are unsure of how to put it back together. Make sure your car will pass inspection in your state before doing this. Double-check that a modification like this won't void your warranty, if it is still active.

• Take your time and don't rush to finish the job. Impatience can lead to big mistakes. Use high-quality parts. Poorly made parts will come back to haunt you later and end up costing you much more in the long run.

Resources

• AVS Shaved Door Kits
• Shaved Door Handle Kits