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[This message has been edited by Amida (edited 03-05-2016).]

Update: After putting it through a 5000+ pull cycle test I decided to use the 5/8" welded steel lever extension. The lever performed very well with no bending or galling of the clevis pin. I only noticed slight polishing of the pin. Lengthening the lever by 5/8" will bring it closer to stock Fiero specs and eliminate the door lock jamming issue.

I did some troubleshooting on the door release issue and found that I was able to get them to work, at least on my own Fiero, but there is a very, very small margin of error between being able to open the door normally, and jamming the door lock. Here is what I've found:

The G6 release lever is designed to be cable operated so in order to connect with the Fiero linkage the lever is modified by adding a screw and a link ( similar to a bike chain link ). The G6 lever is also much shorter than the Fiero. It only moves 5/8" compared to the Fiero's 1.5". So, to compensate for the shorter lever travel when installing the G6 lever all of the slack in the Fiero linkage rod must be pulled forward as far as it will go. The ideal installed position is where all of the slack is pulled forward and the G6 lever is just slightly engaging the door release mechanism.







It's the slight engagement of the mechanism is where the problem exists. If there is too much engagement then the door lock can jam. On the other hand if there is too little engagement then the door may not open even though the lever is pulled all the way back. The two ways to make adjustments are by 1) shifting the entire door panel forward/back, and 2) changing the size of the fabricated steel link. I found that the lock is more at risk of jamming if the fabricated steel link is 11/16" ( hole center to hole center ). However, if the link is 13/16" then the lever may not have enough pull to open the door. So, the margin of error, at least on my own Fiero, is only 1/8" between a working door and a door that jams. I found that using a 3/4" link seems to provide the perfect adjustment where the door will open at 1/8" before the end of the finger lever pull. However, I have no idea how/if this will work on other Fieros since tolerances can vary between Fieros. It will likely take some/a lot of trial & error.

In summary, I was able to get it to work, at least on the driver side, of my own Fiero. Whether or not this wiill work in other Fieros is hard to say. The margin of error is so small that there is a possibility that it may not work in your Fiero. When I get the passenger side molded and and get a panel fitted to the door, I hope to get a better idea of how well the measurements transfer over from the driver side to the passenger side. I am concerned that the sweet spot is so small that over time the doors may get out of adjustment and get stuck which will require further attention.

I don't know if converting the Fiero over to a cable operated system can be done successfully, but I think one way to eliminate the problem, without replacing the g6 lever, is to somehow increase the length of the lever arm. The lever travel of 5/8" just isn't enough compared to the 1.5" travel in the stock Fiero lever.

I'll keep trying to troubleshoot this, with some luck I hope to figure something out.

[This message has been edited by Amida (edited 02-02-2016).]