Datsun Roadster & Early Z Car Interior Door Handle Inserts

1968-70 Datsun Roadster interior door handle inserts (The early Z car handles look to be the same or very close, so this will likely work on them as well.) My roadster came with interior door handles, but the inserts were missing, so I tried making some. This isn't going to be OEM quality, but I think it looks great from the drivers seat, and looking from outside the car, I don't know if I could tell they weren't original.

This is to show how I installed the 3D print.

1. 3D printer with a textured build plate
2. heat gun
3. 1/4" drill bit (or something similar)
4. Blowtorch
5. Pair of gloves that can handle some heat

Download the model here. Print In ASA or other filament that can tolerate the heat it will see in a car. It will need to be printed solid. I just added 4 walls and 100% infill on my Centauri Carbon using "optimal settings", and this seemed to work well. The finish will be determined by the build plate you use. I used the rough side of the included build plate, and this gave a textured look that I was happy with. I would recommend printing multiple as it took me a few tries to get a result I was happy with.

There is a website that allows you to add texture to .STL files from a vector image called Bumpmesh.com by CNCKitchen. I haven't tried this, but you could in theory add a texture that is closer to the original using this, or a similar method. I am happy with the results I got, but I figured I would add this info in case anyone wants to experiment.

I had some rough edges that needed to be cleaned up. I used a piece of 80 grit sandpaper, and a quick pass on all four edges took care of this.

You will need a blowtorch, or other method to heat the backside of a 1/4" drill bit. Insert the pin on the print through the hole in the handle. While holding the print firmly in place from the front, use the heated drill bit to melt the pin on the print from the backside. this will basically rivet the insert in place.

Now using a heat gun, and gloves, heat the print from the top until it softens and bend it around the ends of the handle. I used a bit of aluminum foil tape on the end of the handle to give me a straight edge. You may also need to form it along the length to make it flush. It took me a few tries to get a result I was happy with.

I also left some extra length on the end that will need to be cut off with wire cutters or something similar after you have formed it. This just made it much easier to get right in my experience.

Just glue the end down, and you're done. I tried using super glue, but I've had mixed results with it. It may be better to use some epoxy, or gorilla glue.