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Subject: Doorlock cynlinder cap cover replacement Author: DavidC (moderator) : member since December, 2003 : 12233 posts Posted on: 2004-02-11 12:06:33

The chome metal cap on the driver's doorlock of my '86 735i had been missing for some time, so I decided to fix using a cap donated from a used lock mechanism purchased from a salvage yard.

First, I removed the lock assembly from the door. In my case, the lock didn't work so I had to remove it anyway in order to fix other things inside the door. Still, I believe that its worth the extra work to remove the lock. Trying to line up the spring and keyslot door when JBWelding everything together would be far more difficult with the lock installed in the door. The photo below shows the door with the cover panel removed.


The photo below shows my lock, already removed from the door (more on that procedure later). The small pieces on the right (the cap, keyslot door and spring) are from the donor lock. Everything was thoroughly cleaned using fingernail polish remover, and I lightly sanded the interior surface of the cap and the pot-metal lock to rough them up a bit to give the JB Weld something extra to hold on to.


This photo shows the donor lock (from an '85 735i) on the left with my (bare-metal-faced) lock on the right. You'll notice that the one on the left has plastic whereas mine does not. Though the locks obviously aren't idential, they seemed to be compatible.


The cap, keyslot door and spring from the donor lock were transplanted into my lock. JB Weld was applied to the pot-metal surface of the lock, taking care not to get any of it on the spring or keyslot door, to adhere the cap to the lock. Repeated, gentle attempts to insert the key through the slot ensured that the door and spring operated smoothly and were not misaligned.


Once the JB Weld and the pieces were in place, the assembly was held in place using a clamp.


After waiting 24 hours for the JB Weld to cure, the clamp was removed and the new cap was secure.


The final result, showing the newly repaired lock installed in my door.


David Cecil
Lexington, KY
Titanium silver '01 750iL, 92k miles
Oxford green '97 740iL, 184k miles
Alpine white '92 750iL, 95k miles (for sale)
Charcoal gray '86 735i, 101k miles (for sale)

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