Bogan Plastic Welding to Fix BA/BF Falcon Interior Door Handles! Ford BA BF XR6 Turbo Cheap as Chips

Aren't BA/BF Falcon interior door handles the worst? Today I am attempting to fix them on the cheap... with a bit of bogan plastic welding! All you'll need is a soldering iron, and you're good to go. #MOTORINGBOX
Timestamps:
00:00 - Introduction
01:05 - Removing door trim
03:37 - Why BA handles break
04:48 - Bogan plastic welding
15:17 - Refitting door trim #1
16:42 - Re-doing the plastic weld
17:02 - Refitting door trim #2
19:03 - Conclusion
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🚘 About MotoringBox
MotoringBox is an Australian based KZbin channel run independently by Sean McKellar since 2019. It focuses on quality content about Australian car culture and some of the incredibly unique vehicles we manufactured here. I work a day job and publish videos in my spare time, so thank you for your patience and I hope you enjoy my videos.
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MotoringBox
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Website: www.motoringbox.com
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Please note: I enjoy working on cars but I can't promise that what I do will work for your particular car, or that you won't harm yourself, someone else, your car, or your warranty doing it. Please be safe, be responsible and if you're not sure what you're doing, get a qualified mechanic to help you out.

[@MotoringBoxTV]

Thanks for watching! Like, comment or sub to support the channel. 👕Or grab a shirt from www.motoringbox.com/shop

[@knight2425]

“It’s a bit like doing it in the dark, your not quite sure where you’re going until you feel it then your away” lol

[@silvernoob1603]

i have got to admit...my mind was in the gutter a few times during this video..........lol

[@lunch2102]

It's to be expected when someone mentions a screw in a dark passage

[@hortiboi]

I had to remind myself it was KZbin not YouPorn 🤣

[@jasonblanch8769]

“Let me put this steaming hot member down the hole” 😆

[@jean-marcandjoshua-petsjournal]

More than a few?

[@bengibson3955]

100%. The innuendo was flying thick and fast.

[@antoniof7479]

I asked my nephew to get out of the room while watching 😂

[@hortiboi]

I've been avoiding this fix on the front passenger side door of my BA Fairlane and everyone's getting sick of my warning them to be delicate with the door closing. Bogan plastic weld gods send me strength 😂

[@shreda125hilux7]

Nice work mate , if it works it works , this is how all us "normal" car enthusiasts fix things , most DIY/Budget and we wouldn't want it any other way

[@PaulinesPastimes]

Nice to see that all that feeding in of a red hot member did the trick. 😄👍

[@MotoringBoxTV]

Glad to hear you enjoyed that part 👍

[@FuManchu5ltr]

Breathing in the fumes would be the most bogan thing to do.

[@GavincredibleAU2]

This channel represents the Aussie tradition of having a crack 👍

[@sch-corp]

God, this is bringing back memories/PTSD. I had the exact same problem with one of the rear doors on my BF XR6T. I genuinely can't remember how I fixed it - probably just used some araldite and hoped for the best.

[@lairdgault7862]

Honestly I don’t know how you don’t have more subscribers, your videos are so good

[@MotoringBoxTV]

No clickbait, plus I film things I like as opposed to what I think people want. I guess? 😃

[@ollyd4073]

STAPLES!!! Seriously, those big 1-inch wide ones from heavy duty packaging. From past experience re-bonding plastic can be a prick if it needs to be very strong afterwards. I repaired a flip up* headlight cover from an old LTD by doing something very similar (one of the pivot tabs on the back had let go) but I cut and formed some F(*&ing big stables, melted them in below the surface and added some extra plastic ontop. Bit like ribs. If anything it's now stronger than it was from factory, at least in the repaired area. *Edit, up not down Great seeing the renewed DIY focus dude! This channel will go far :-)

[@tonykitchner1697]

Mate have fixed dozens of them . Generally the best way is to use an 1/8th inch drill and actually drill down the centre of the shaft of the door handle mount and then use the correct size self tapper with a large washer and screw into the hole. Even for the one that has no shaft from memory you can actually drill through the actual handle base and use a long screw even though the screw comes through the handle it is covered by the boomerang trim cover that you clip back on. It will never move after you do this. But you can use the Bogan welding method for lots of other uses. Yo can the swap the centre trim piece of the door trim just go around each of the plastic welds (like the one you drilled out) and then melt them and pull away on each one you melt to leave as much plastic as possible. Once all melted you can remove the trim piece and then replace it with one that matches the colour you need. Have done this on EF's, BA's and BF's. The other are to use your soldering iron is on the plastic seat trim cover as the crack in all B series and even FG's. What we do is remove the cover then place it on a bench and make sure the is crack closed as much as possible. By just soldering the crack will not provide enough strength and therefore we have used small strips (40ml x 10ml) of plastic from the under tray of an EF as this is pretty thick. Firstly run the soldering iron along the crack on the inside to seal it and then place the strips vertically usually 3 -4 strips depending on the length of the crack and "solder" these on. By being placed vertically they ad strength rather than just running along the crack line. While the trim cover will now be the stronger and the correct shape the actual crack would most likely still be visible. What we do is run a fine tip soldering iron along the crack to seal it and then paint the trim using plastic trim paint from Supercheap. Also, if the trim has cracked then most likely the seat bolster has also collapsed as the weld the frame break from people sitting on the edge of the seat when getting into the car. The simple fix is to to remove both front seats and swap over the seat bases as normally the passengers side side one is in good nick. The seat bases are identical so no issues there. You can weld the frame or simply swap over as the drivers side base would now be up against the centre console and really not noticeable. It takes around 2 hours for one person to do.

[@teikoh5690]

Thanks for that! Was planning to fix the cracked seat trim on my BA ute this weekend after having fixed door actuator yesterday. Fixed collapsed seat bolster a few years ago by rebuilding with some gardening wire 🙂

[@dangerousdave1004]

And here i thought you were welding plastic Bogans!

[@SneezerNZ]

Nothing bogan about that fix mate. Top job!

[@SGTschultz1986]

Well done

[@typhoon4292]

Never knew why someone never made an after market door card seeing how big a problem these are. Most people either do a rough patch up job depending on the break or replace the whole card itself

[@JohnDoe-tn3tx]

I don’t know if an entire aftermarket door card is needed but someone like Rare Spares could make a aftermarket grab handle that could be affixed to the existing door card using screws rather then the shitty plastic spot weld that ford originally used…

[@CathodeRayNipplez]

Trim breaking off a Ford? Never! The BA is actually not bad compared to our F250 in which near every interior part has now broken off.

[@alpharaptor7510]

Awesome video I own a 2005 BF wagon ex taxi and all the door handles are still good Happy Australia Day

[@MattBlack6]

Going to Willowbank Sat night (30th) to see my mate's 500hp BA do some ¼ miles. Yiew!

[@heavymetal9622]

I broke a BA door handle like this on a TAXI one time just by simply closing the door. The driver said “don’t worry it always happens, just throw it on the floor”

[@TheKnobCalledTone.]

TIL internal door handles are to BA Falcons what external door handles were to XD Falcons.

[@Triple-N]

Ipswich style welding. 👍🏽👌🏽

[@darkwingduck3320]

You just saved me $159 bucks and $15 postage thanks mate cheers

[@daledenton9246]

Shelley’s Liquid nailsworks a treat. 😂👌🏼

[@rEdHoUsE_1969]

I can't count the amount of times during this video I shouted out "... that's what she said ..."

[@ak47kalashnikovak47]

Absolute legend! I was about to drop a couple hundred on replacement door cards/grab handles and tried your fix and it worked perfectly!

[@stephendunn935]

Trim removal tools work a treat

[@hadangodsey2651]

this video is an absolute life saver!! had my passenger door handle snap clean off on both top and bottom, finding a cream door card for a ba xt is absolutely impossible!! found out after fixing mine right after i watched this video that the screws were never put in for the handle so it was the plastic bits that just gave out! door handle is now back the way it should be

[@MotoringBoxTV]

That's awesome, well done mate!

[@istubbii]

Legend, this helped out so much. Simple and easy guide 👍👍

[@VX3800]

VT-VZ ones are the best because they’re fully integrated with the door card. Good styling too

[@gamingdad87]

Handy method to fix broken plastic. Thanks for the video, as usual great content!

[@dancing-spaghetti]

Went to slam the door while driving since I didn’t close it properly and learnt about the build quality the hard way

[@MotoringBoxTV]

The worst part is trying to pull the door closed when it has only half latched. Never do it! Always open the door again and close it properly.

[@urabusliberty9258]

Currently reconsidering buying a b series

[@davidorama6690]

Very timely video. I need to undertake some bogan plastic welding myself.

[@docdeth5146]

Great job mate that old plastic can be a real bastard sometimes 👍👍👍

[@vlockley]

The back door trim in my Bf is the same. I will definitely give this a try.

[@callummartin416]

The innuendo is well-integrated, clearly enunciated and brought forward the most hearty of guffaws. Marvelous work, good chap =D

[@PM_Anthony_Albanese]

I'm glad I watched this! Cable ties as filler rods will be a lifesaver when my time to fight these ridiculous door handles finally comes.. Thanks for the video!

[@MotoringBoxTV]

Have you ever used a soldering iron to successfully plastic weld something? Let me know in the comments below!

[@busnutter4216]

Bert's mower have not use a soldering iron before to repair on car parts in the B series Ford or on anything to do with car parts but it is certainly useful information thank you for sharing

[@busnutter4216]

That I certainly never used soldering iron before on any car trims - the game apologies for my Miss typing I am yet again using audio text so if I don't speak up clearly then something is going to go wrong - my apologies buddy... Cheers

[@MotoringBoxTV]

No worries mate, I can understand it! Thanks for the comment.

[@morantaylor]

Yes but the iron is not much good for actually soldering after it. I am currently contemplating the same fix for my Territory drivers door the arm rest section has separated.

[@MotoringBoxTV]

@@morantaylor you can easily replace the tip or at least sand it back down until it's clean. But yup, my iron is old anyway and will be replaced.

[@stephendunn935]

Great job and an excellent idea to repair plastic thanks

[@jaradrockley]

This has helped me soo much. Thanks heaps good sir ✌️

[@fantac_electronica]

This has happened on the exact same door of my BF fairlane. Very keen to try this fix now

[@oooh-behave]

These handles typically break when people yank on them to pull the door card off (replacing actuator motors or putting some sick speaker installs in). To mitigate this, you use a pry bar at the side and run your finger around from the bottom to the top uncliping each clip. Then you pull the whole card up and away. Don't be tempted to pull on the handle, it will break like this and you'll be pulling your hair out to fix it or to find a replacement card at a wrecker.

[@munnsie100]

Gotta love Ford's plastics! The interior plastics in my EB (like your Fairlane) have metal clips on plastic standoffs that always break off. Never remove your A-Pillar trims unless absolutely necessary, they break pretty much every time and they never go back on properly. Apart from those painful clips, the rest of the plastics aren't so bad. I've plastic welded a few things with a soldering iron before, works well!

[@TBRHIPHOP]

Cheap as Chips...... Sexual innuendo edition! 😂😂😎👍🏼

[@247xRTS]

Love the videos mate, definently handing out some great info to people in need, Iv done the screw method on my Fairmont Ghia door card and it held up just fine :P

[@MotoringBoxTV]

I think mine would have held too. But no, I had to go and mess with it, didn't I!

[@blunt3777]

Brilliant! 👍

[@xboxrlz]

MotoringBox one thing you can also do is use a paper clip and press against that so it reinforces the join, did it on my old dirtbike to fix the plastics with great success

[@AshleyLacey-bn5gq]

Amazing talent to make a ford falcon door trim video sound dirty.. 😂😂

[@Noelly1980]

Very creative mate. I like it. Sort of thought that was going to happen on your first attempt but filling it with a cable tie might have been what it needed. I was thinking a little super glue than the soldering iron cable tie bogan plastic weld might also be an idea. The card on that door looks mint too might I add. 👌

[@josemanuel5749]

16:27 - People dying inside x2

[@jamesvozar1]

This is a quality Mcgyver fix, will be as strong as when new. great tip as always.

[@THE-GO-BRO]

Good job man. Nothing wrong with that. If it works it works!

[@paulhardie]

So much innuendo, I thought I was watching a Benny Hill re-run 😆 Really enjoy your videos Sean 👍

[@josemanuel5749]

12:48 - People dying inside xD

[@shreda125hilux7]

I cringed so hard

[@Raith_05]

Ive had both the front handles break on me and went to a wreckers and $70 later I got 2 door cards in good condition that Ive whacked on its been good eversince

[@bigbannana4949]

Put a bit of grease on the screw where it touches the plastic underneath so that won't try too turn and grab as on final turn it will slide instead of twist and snap

[@johnblood3367]

Awesome, I actually learned something how to plastic weld, use cable ties for it. I think my 2007 BF2 Ford Fairmont Ghia has done more km's than yours , I'm at 227,000km. I still thankfully have all my handles working, except a cracked chrome drivers door handle that opens door. I learnt a lot from this video. I hope to beable to buy a new (2nd hand ) handle an try to get spare ones for other doors. Shaun your videos are SUPER AWESOME, a wealth of knowledge an I love how you have kept ALL your cars even the Commodore in top condition. Keep up the great videos

[@TimsBitsnPieces]

I have done several repairs to my AU3 and my 80 series LandCruiser in a similar fashion, I use my soldering iron and also a heated flat blade screwdriver to flatten out areas after I have run the soldering iron over it or just used the hot flat blade screwdriver.

[@nickbishop6784]

Good job

[@FunnyCatVidzz]

Did a full lap of Oz in my old BA Falcon wagon 23,000 kms over 6 months. Beautiful cars

[@TommyMacsWorkshop]

I fixed my old falcon by taking the panel off, and driving a small self tapping screw into the back of the handle, fixed it well!

[@joeveto]

I love the honesty of this video, when you install the handle and it breaks. Happens all the time. This is way better than the couple who picks up a cabin cruiser for $500, repair it with parts they find laying on the side of the road, and sell it the next day for $75K.

[@midnightdemons9147]

Had to do something about my rear handle on my bf and ended up just using a heap of silicone to hold it in, works pretty well

[@davidmacfadyen165]

Wow, i never thought BA falcon was so cheaply made, great video. EL falcon all the way

[@dennisfreebairn8754]

My door handle is a bit far gone but great video Simon

[@ThePowerbloke]

Another excellent and informative DYI vid mate! Thanks for sharing. :-)

[@MotoringBoxTV]

Thanks 👍

[@jamesfrench7299]

How on earth did the BA and BFIII cabs I drove never encounter this?? I drove each for three years. They must have had an industry exclusive remedy. I admire your willingness to get in there and tackle a job even if it may not turn out to be the best method. You always get the desired result.

[@Jn-gu9th]

I would like to know..more on this

[@martyburgess341]

I reckon car manufactures design it like that so it is easier in the long run to fix. But some don't like the car being tampered with. Tesla(The Apple of the car world) for example.

[@Junfanfrankiejess]

I used smaller threaded screws that wired fine And for the cap I used super glue and reinforced it with bread clips it's a tank nowtganks for the inspiration

[@DeckoTD]

'safely' placing the hardware on the ground becomes complicated when you do it on your front lawn, sad stuff.

[@MotoringBoxTV]

I always drop things, so I just leave them there. It's a dangerous habit.

[@shannonspear8751]

As soon as he started to take that screw out I new he was gonna snap when he did it up again .

[@dannbarra11]

"piping hot shaft" LMFAO hahahaha

[@busnutter4216]

Thanks very much for the information buddy it would help me fix any of these cars up in the future if I did decide to buy a b series Ford of any sort most likely any BF series Ford Fairmont Ghia all series's came out with 6 speed Automatics which I prefer the 6 speeds... most likely the next car I would probably be saving up for would be a 4WD... Mitsubishi Pajero manual... that's ok we are all different as the world would be boring if we were all the same... keep the good work up buddy

[@braydokiernan8577]

I done my bumper, wheel well and today front mud guard. Flood water started it !!

[@cameronholmes7483]

Only had to take the RHR door trims off to fix a little bit of rust and replace the central locking spiral cog in the motor - that will be next. Only had to replace the carbon fibre look trim insert on a Holden WM Caprice - used some screws and liquid nails to put it back together.

[@paddy-uf8el]

Pov watching this before you hit 1 million subscribers 👀👄

[@glennmk5167]

Mine done the same but left hand side lol, I just glued back in place, told passengers use right side

[@bossdog1480]

Nice one boss. Useful information. You can also use superglue and baking powder. It's a little messy but does work. I'm surprised that none of my door handles have busted off in the wagon, especially the drivers side because it gets a hard life. Door locks are something you can look forward to repairing if you haven't had any stop working yet. The little plastic worm gear breaks. I've just had another one break so I might try welding that. I would have to do a bit of reshaping after as the shape has to be right for it to work properly. Thanks for the demo.

[@petercairns7509]

There is a 2 part super glue like product called Rapid Fix. 1 Bottle with super glue type liquid, 1 Bottle with a fine powder (crushed glass?) Lay a bead of the liquid out then sprinkle powder over and progressively build up layers to the required amount. Dries instantly as hard as rock. Just roughen up the plastic surface being repaired. Life saver for these sort of jobs.

[@madhardcorenick]

I've heard that there been numerous of people saying their door car handle has snapped. My BA with nearly 500,000km has never done a single one (yes I know I'm really lucky). However, I'm sure there should be a good solution in terms of fabricating a bracket or something so it never happens again. I don't think the materials that are used here are crap exactly, rather I think the way Ford mounted them weren't the best. However, I still reckon BA are far from crap since you do still see stack of these cars on Australian road and most of these issues that do occurs are a matter of age, after all BA are not far off the 20 year old mark.

[@todd_harrison4500]

I was relatively lucky, I was able to put the right size screws in both spots and it never failed again 👍

[@jameskape4443]

This may sound a little stupid what i used was liquid nails from the back and it's held on perfectly its been on now for about 2 years

[@MotoringBoxTV]

Hey, if it works there's nothing stupid about it!

[@ayzaadali9184]

did the same still holding on

[@alexandreb.1101]

I just bought two of those for my Mercedes for the same reason...

[@stormageddon7116]

That CRACK sound was heartbreaking. LOL. Felt it when i repaired my FG front drivers side door. Cable tie as solder is a great tip I hadnt heard before. Nice one Sean

[@MotoringBoxTV]

For a split second I was contemplating just ignoring it and continuing. I didn't wanna face it lol

[@stormageddon7116]

@@MotoringBoxTV We all contemplate ignoring it lol.

[@darth3pio]

I was thinking about this problem the other day, it seems you have a knack for posting about what's on my mind.

[@MotoringBoxTV]

I think us BA owners all go through the same shit.. hahah

[@darth3pio]

@@MotoringBoxTV I reckon, still happens on the BF

[@johncostin8294]

I have an fg falcon. The door card removal process is similar but they don’t have that handle anymore.

[@smithy2]

You know ive always thought about wielding abs plastic but never tried it, my BA has a broken cup on the bottom of the front door, I also need to replace a speaker grill... maybe your next video 🤔😁

[@alpharaptor7510]

Also I had to replace front door panels on my AU

[@paulmcgaw6976]

Excellent video as always! 16:30 minute mark though 🤣. We've all been there. Still the saggy roof lining sagging, brake booster adjustment fix, power steering shudder at low speed, non existent hand brake, rear diff clunk, milkshake, balljoints to go until you get into the BA Club! Still love 'me though!

[@MotoringBoxTV]

I get the shudder sometimes

[@paulmcgaw6976]

@@MotoringBoxTV brake shudder? I replaced my rotors / pads but didn't find out about the fix with the brake booster till a year later. So 7000km and warped rotors again.... Only noticeable when going down a huge hill and braking.... I let it be but coming into Adelaide it would be a mess! Steering shudder I've had since I owned the car. Needs a hose but I can live with it. BA's have their faults, but very few times it'll leave you stranded.

[@SHOCKcustoms]

Do you find the black shaft to have more girth? Does it fit into the white hole deep enough? Or will it break after many uses? are there any concerns with a messy member ? Cheers

[@blek4922]

did this in all the falcons and territorys i had haha but i found glueing it with areldite worked better. it drys hard and holds

[@AdamAus85]

I tried a similar technique to repair the engine under cover on my E39. Holding up okay save for one edge of it. I made sure to use the same plastic type as filler.

[@MotoringBoxTV]

Nice work! Yup, using similar plastic is a great idea.

[@zach1181]

there should be aftermarket aluminium handles made for these ba falcons

[@josemanuel5749]

This remind me when i had to remove the door panel of my Chevy Sonic because something in the interior got loose :(

[@zoomosis]

I had a similar thing happen in a Peugeot. A nut inside the door had become loose and jammed against the window when it was rolled down. The previous owner had forced the window down, tearing a gash in the window tinting film where it scraped against the loose nut. Fun times.

[@falcon1473]

Johnny Sins mending a BA handle, who woulda thought ;) Great video though, some good ideas in there. Brain fart at 16:10?

[@Chriswales]

Great video, the bit where the screw snapped it was classic. 2 part epoxy glue like Araldite would be a better option, scratch the plastic to give it a good key and smoother the MF in it.

[@glennt69lol]

Nothing beats that feeling of the first screw of the day...

[@MotoringBoxTV]

Hahaha, I wasn't even trying to be suggestive with that 😦

[@GelusE05]

that crack broke my heart, i was hoping u wouldn't go too far

[@chrisstreetable]

Hi all when it comes to plastic you need to find what solvent melts the type of plastic you have and most plastic will have some letters on the back telling you what plastic it is so for example if its ABS (Acrylonitrile Butadiene Styrene) very commonly used in hard plastic car interior parts and one of the only plastics that can be chrome plated , now acetone melts ABS so if you put a small amount of acetone into a small container now add some pieces of ABS plastic now as it starts to melt stir it adding more plastic or acetone until you get a uniform glue like paste and what you have created is ABS plastic glue or you can buy model car kit glue like airfix humbrol etc now this will glue the door handle parts back together but the design of these door handles is weak so some extra reinforcing is strongly advised, now as you don't see the back of the door trim and the handle stays with the door trim the best thing i found was to use Selly's KNEADIT epoxy putty from Bunnings ,rap it around the screw tubes and also put strips in the inside of the handle then the other end of the strip onto the inside of the door trip plastic ,this makes a rock solid repair . ps this door handle is for closing and opening the door and the 2 most important screws on these door trims are the 2 screws that hold the handle to the door without them you will rip the handle off the door trim so if you lose any screws these 2 must be fitted as the rest just hold the trim and can be replaced later .