How to Shave Door Handles on VW Beetles

To shave automotive door handles is to completely eliminate the door handle and have a smooth finish on the door. This not only cleans up the look of the side of a Beetle but can also eliminate someone from getting into your car. Shaving the door handles on a VW Beetle is a complicated but rewarding process, but if you know how to shave door handles on Beetles you can shave the handles on just about any other car also.

Difficulty: Challenging

Instructions

Things You'll Need:

• Screwdrivers (flat and Phillips head)
• Weld-Thru Coating
• Welding machine, gloves and shield
• Sandpaper (120 and 400 grit)
• Sanding block
• Primer
• Body filler
• Paint
• Grinder
• Sheet metal

1. Open the door and remove the door panel. Locate and remove all of the screws on the panel, disconnect any wires behind the panel and then pop out the clips around the edge of the panel. Roll up the window completely. Remove the door handle hardware from the inside, and then pull the handle on the outside to remove it completely. Remove the metal rod from inside the door that was used to open the door. It will no longer be needed and may interfere with the window or other parts inside the door.

2. Cut a piece of sheet metal to fit the two small holes where the door handle was. On newer VW Beetles, there is also a circular indention between these two holes. You can leave it or use another larger piece of metal to cover it and make it smooth also.

3. Use a grinder to remove all of the paint away from the holes left by the door handle. Grind the paint at least 4 inches away from the holes. Spray Weld-Thru on the bare metal and on both sides of the metal pieces you are using to fill in the holes. This protects the metal and prevents rust. This primer can be welded and not catch on fire like regular automotive primer.

4. Weld the metal pieces into place, making a welding line completely around the metal piece. Allow the welds to cool before continuing.

5. Grind the welds down with a grinder until the surface is completely smooth. Apply a coat of body filler over the entire area and allow it to dry.

6. Sand the body filler with 120-grit sandpaper and a long sanding block until the entire area is completely smooth and flush with the rest of the door. Spray automotive primer on the entire area and then sand again using the sanding block and 400-grit paper.

7. Paint the repaired area with paint to match the car. Have a door-popper kit installed on your car immediately after (or before) shaving the door handles. Most automotive custom or audio shops can do this. Installing door-popper kits should be installed by professionals because of the difficulty of the electrical wiring that is needed. Unless you have a keyless entry system already installed on your car, there will be no way to open the doors. The door-popper kit gives you a way to open the doors in case the battery goes bad in the keyless entry pad.

Tips & Warnings

• Always use a breathing respirator when sanding, priming or painting a car.
• Never weld without welding gloves and a welding face shield. Welding can severely damage your eyesight.

[tripsdada]

on 9/4/2009 Great article, but it should be noted that welding a continuous line on sheet metal can warp it badly. A heatsink, such as a block of brass can be used to reduce warping, or you can make a series of small "spots" around the outside of the filler metal using a star pattern. For example, you would tack the left and right sides, then the top and bottom. Halfway between the top and right, then bottom left, bottom right, top left. Mix and repeat until there is a continuous beat all the way around. This will also minimize the amount of body filler needed to cover pits and smooth the body.