I mocked up the OEM door handle on the door panel with a bracket I made and double-sided foam tape and it just won't work. It sits a little too low and is just outboard of the seat. The panel will be 3" thick there, below the armrest, and when I pull the handle out it nearly hits the seat. I'm afraid that if we add some foam to the seat bolsters it's going to hit it and eventually cause some wear on either the leather or the handle, or both. The actual location would be just about the same as in my Silverado, but I pull that handle straight up instead of out away from the door.
So I think I'm down to one handle now...at least that was decided for me. I have been in contact with Clayton Machine to try to get some dimensions for their EL-503 handle. They sent me an exploded view, and it's a pretty cool concept...different from any other door handle I've seen. I need to know what the thickness of the part it to be sure it fits where I want to put it. I have two choices on location, one immediately behind the grab bar like on the black panel I posted above, and the other just below the vent window. I will have a vent window motor there (no crank), so I have to be careful where I put the handle.
The other remaining issue is how to solidly attach the lower end of the grab bar to the door when the panel is installed. I think I'm going to make a removable arm rest section so I can get into that area to install a screw. I'm hesitant to make an access hole that can be seen on the panel.
Once I get the final shaping of the aluminum done and the clips installed, I can start pouring foam. I may have to consult with a metal-shaping expert on the final shaping, because I'm having a helluva time with it. I have it close, but not as close as I want it.
I noticed the pic of the black/red panel didn't post right, so I'll try again.
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