Aftermarket Outside Door Handle Modification for "Sticking Handle"

[Boostaddict]

I installed a pair of aftermarket outside door handles a couple weeks ago and have been struggling to get one working properly.  Basically when everything is tightened down properly the door won't open (from the inside or outside) when locked.  The cause is something in the handle mechanism (the stamping, cotter pin/spring, push button assembly) sticking slightly raised which leaves the rod under tension.  If you jiggle the button hard the rod will fall and the door can be unlocked.

I did tons of searching and found a thread from several years ago where a guy had a similar problem and his fix was to grind off some extra metal on the inside of the aftermarket handle mechanism that was sticking on the inside of the door.  I compared several handles and experimented with some modifications but nothing has worked yet (seems to be working slightly better though).

Can anyone explain or show exactly what needs to be trimmed/ground for proper use?  As a last effort I'm going to try swapping the handle guts from an original gm part to the aftermarket casting and see if that works. 

On a related note, does anyone know where you can buy replacement metal clips that hold the vertical rod from the outside door handle to the main door latch assembly (the clips that are a pain to slide off)?  I lost one and had to make a new one from a similar clip I had around.  I searched various sites and the only thing I could find was to buy an entire new latch assembly that comes with the clip.

Thanks,
Wayne

[thirsty]

On a related note, does anyone know where you can buy replacement metal clips that hold the vertical rod from the outside door handle to the main door latch assembly (the clips that are a pain to slide off)?  I lost one and had to make a new one from a similar clip I had around.  I searched various sites and the only thing I could find was to buy an entire new latch assembly that comes with the clip.

I would like to know this too. When I assemble my doors I will need some. My doors had really small wire wrapped around them. It must have taken a lot of patience for someone to do that.

[Bitzer!]

Shave em and use a popper kit 

[Boostaddict]

Not for me thanks.  I really just want to get this door handle fixed.  I'll post some pictures tonight showing what I'm dealing with.

[Irish_Alley]

I installed a pair of aftermarket outside door handles a couple weeks ago and have been struggling to get one working properly.  Basically when everything is tightened down properly the door won't open (from the inside or outside) when locked.
what am i missing here? why would it open when its locked or is that a typo?

On a related note, does anyone know where you can buy replacement metal clips that hold the vertical rod from the outside door handle to the main door latch assembly (the clips that are a pain to slide off)?  I lost one and had to make a new one from a similar clip I had around.  I searched various sites and the only thing I could find was to buy an entire new latch assembly that comes with the clip.

i know AutoZone sells them in their bolt section in the asle on the little shelves that spin around

[Boostaddict]

I might have the handle working now.  Attached is a picture showing approximately how much material I removed from the handle stamping.  The way it looks in the picture appear to work okay (at least for now).  I opened/closed/locked/unlocked the door a few dozen times and I couldn't get it to stick any more.

[Boostaddict]

For reference, this is what an original GM handle looks like in comparison.  I don't have one showing the aftermarket handle prior to grinding but there was a lot of material I removed (including sharp corners).