Armrest fix/fabricate

[fsjeep]

I'm not finding anything on here about this (must be searching for the wrong words...)
Surely someone has had to fix this. I got a 94 ext cab last week and the door handle/armrest is ripped off. I went to a junkyard to get a replacement panel but every door I saw had the same problem. From what I can tell 2 screws run throught the plastic panel into the armrest and one screw runs through the plastic armrest into metal connected to the door. Has anyone fabricated a stronger handle or reinforce the existing one? Plastic just can't hack it for those heavy doors. My pins are still pretty tight but it does hang on the striker. I found the jackup the door w/a 2x4 trick and will give that a try. Should decrease force needed to shut the door.

[ChevLoRay]

I think you are on the right track. The doors on these trucks are well-known to sag and drag. That means you find yourself bumping the door with your shoulder when you want out and pulling hard to open it.

First thing to do is to restore the door to the right place in the door opening. Like you said, a 2x4 is one way. There are specific tools, also. In all likelihood, your pins and bushings are worn, too. This aggravates the problem.

After you get that fixed, then you can work on the handle issue.

[Chevy350V8]

you could go on LMC truck's site and buy new replacment door panels.

[JohnC]

They do make a door aligning tool that will help you get the door back where it needs to be. However, like ChevLoRay stated you need to replace your bushings first, or you will be right back in the same situation.

As for the door panel. On my old 94 I ran a screw with a larger, approx 1" or 1-1/4", fender washer on it that wouldn't pull through the hole in the armrest. The problem I kept having was that the head of the screw would pull through the armrest/door pull. The larger washer kept it from pulling through, and I never had another problem with it.

[fsjeep]

Did the floor jack 2x4 trick, way easier to shut the door!! I've grabbed the door while open lifting it and only noticed very minimal movement. They feel pretty snug to me still. In the past I've swapped pins out of a ragged door of a 80's monte carlo, i'd rather not mess with the pins of those heavy ass doors.
I checked out the LMC door panels but I'd rather use that $380 for tires. Budget building here!
I was thinking of cutting out a piece of sheet metal to fit the bottom of the handle but a washer would work too, and since I don't have access to too many metal fab tools...
Thanks for all the help!