In an effort to save on cost using an insert panel was not part of the original plan. However, the plan had to be changed after having difficulty with a stitched insert during the upholstery process. Therefore, I had to go back and redesign a separate insert panel into the plan. Here, an ABS insert panel, cut by a waterjet, is being test fitted. A finger recess had to be formed on a vacuum jig, and a couple of mounting holes needed to be moved due to interference with the door mounted cross bar. So, the effort to save on cost actually ended up costing more. Funny how that happens.

[This message has been edited by Amida (edited 11-22-2015).]

UPDATE: The release levers will be outfitted with 5/8" welded steel extensions to increase lever travel similar to stock specs.


Unlike a cable actuated door release where positioning of the lever is not so important the Fiero door release mechanism uses a pull rod and positioning of the lever is very important. Positioning too far to the rear creates too much slack and the lever will not open the door. On the other hand positioning too far forward will pre-load the mechanism and interfere with the door lock causing jamming. The ideal position, I have found, is where the lever is moved forward just enough to remove all of the slack in the rod. At this position the door should open within the last 1/4" of the finger lever pull.

Here, I am experimenting with different size connecting links to find the right length. I've made several lengths from 5/8" - 1 7/16". In the photo I am using 1 1/8".

The BIG question is will all Fieros use the same size link or will there be variability?

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

Door release lever testing continues. This time with a 5/8" welded steel release lever extension which will increase the lever length to near stock Fiero specs. Holding up very well after 2000 pull cycles so far.

[This message has been edited by Amida (edited 12-03-2015).]