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300TDi CSW Phil

Member Since: 03 Apr 2016
Location: Bracknell
Posts: 818

1995 Defender 110 300 Tdi CSW Epsom Green

Door handle (exterior) help required

I bought 4 new door handles (All makes 4x4 versions) to put on the new doors but not all is well.

I have a gap near the lock barrel part on both of the fronts and am fearing I will end up with the same on the second row doors when the time comes in a few days time.

What have I done wrong or not done that is causing this?

I did trim up the moulding flash and rounded the corners of the actuator on the back of the push button.

Picture below shows the gap.

Click image to enlarge

Any ideas great fully received.

Has anyone one got anything to say about the LRParts aluminum ones as this may be my backup plan (really can't afford/justify Optimill ones right now). 1995 300 Tdi Epsom Green- Slowly Turning into Keswick Green - It's a keeper.
Wide Track Sankey- In bits- Gone to a new home
M0XQS

22nd Jul 2025 8:31pm

donmacn

Member Since: 07 Nov 2017
Location: Nth Scotland
Posts: 1894

Hi Phil,

I can't comment on the alu. versions you've mentioned. I did go Optimill in the end, mainly because of the more secure key/lock they used.

However prior to this I had real issues fitting a "quality" set of plastic handles. They were just too big (long) for the door cut outs, hence the bending in the middle and the gap you've highlighted.

I took some pics and waffled on about it in my 'rebuild' thread. On this page:https://www.defender2.net/forum/topic58538-75.html

Hope that's of some use. Donald

1994 Defender 300Tdi 110 SW - owned since 2002 - 230k miles and going strong
(The 'rolling restoration' or tinkering thread: http://www.defender2.net/forum/topic58538.html )
2000 Range Rover P38 4.0L V8

in the past..
RR classic - fitted with 200Tdi
1984 RR classic - V8 with ZF auto box
1993 Discovery 300Tdi

not to mention the minis and the Type 2 VW camper...

23rd Jul 2025 1:15pm

TexasRover

Member Since: 24 Nov 2022
Location: Paris
Posts: 1284

2002 Defender 110 Td5 DCPU Chawton White

Inevitably there are poor quality/fit parts available on the market. There is a enough of a draw to make parts since there is a demand, but at the same time its not as if we are all willing pay top dollar so if it's cheap, quality can be questionable.

It does not surprise me your plastic replacement parts are a poor fit. Personally I prefer 'used original' (typically from my private stash) over cheap aftermarket where I can.

The safer bet is to go to specialist suppliers, at a higher price, but often these are better than original.

However there are also good parts out there so don't give up. Just admit defeat sometimes. Call it the 'thrill of the case', of classic car ownership.

23rd Jul 2025 1:48pm

300TDi CSW Phil

Member Since: 03 Apr 2016
Location: Bracknell
Posts: 818

Thanks chaps.

I have given up on plastic ones and hit the button

on a set of four aluminium LR Parts ones with a new ignition/steering lock and barrels.

I will offer one up when they arrive to one of the second row doors from DDS and assuming it lines up properly they will be staying.

Hopefully the finish isn't too different to the front Optimill hinges but at this point that is a secondary concern as I just want handles that fit properly and the 2nd row hinges I have are silver so need to be turned into black anyway.

Once I have one (or more fitted) they will be be pictured in my colour change thread. 1995 300 Tdi Epsom Green- Slowly Turning into Keswick Green - It's a keeper.
Wide Track Sankey- In bits- Gone to a new home
M0XQS

23rd Jul 2025 3:29pm

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