Door handle

[FastTex]

So….I’m with my family in the airplane, taxing to take off. Door is open for fresh air. I went to close it after the run-up and…see pictures (please notice the small crack on one of the pin holes on the handle). I taxied back, called the FBO to free us up (we were stuck in the cabin) and then put the Mooney back in the hangar. I guess better there than at the destination.

Where can I find another handle and has anyone found a better way to fix it? This is the second time it happens to me, fortunately the first time I was by myself.

Thanks!

[Jim Peace]

I keep a vice grip nearby every flight....still wonder if that would work in place of the handle if needed

[N201MKTurbo]

I would take it to my friend John. He is a miracle worker with aluminum and a TIG torch.

He has a toaster oven for parts like this. He puts it in the oven as high as it will go, lets it sit in there for 10 minutes or so, then takes it out and welds on it, then puts it back in the oven and turns the oven off and lets it slowly cool for 1/2 hour or so.

 

BTW.

I had this happen a few times myself with my old F. I put a Craftsman #0 Philips screwdriver in the side pocket. If the handle failed, I could stick the screwdriver in the roll pin hole and get the door open. 

[N201MKTurbo]

4 minutes ago, GEE-BEE said:

I can Cnc a new from sample in 6061 alloy

 

GB

 

The key is the material and not cast crap

here is a pic of the beech Cnc tiedowns

not cast or stamped crap

 

It would be interesting to do an off angle pull test on yours and the stock ring. The stock is steel and yours looks like aluminum. Have you done that testing?

The tensile strength of 6160 is half that 304 stainless and some carbon steels are almost 4 times as strong.

Edited May 9, 2021 by N201MKTurbo

[Boilermonkey]

I've carried a vice grip in the front pocket on my seat for years after this happened to me.  

[EricJ]

36 minutes ago, N201MKTurbo said:

It would be interesting to do an off angle pull test on yours and the stock ring. The stock is steel and yours looks like aluminum. Have you done that testing?

The tensile strength of 6160 is half that 304 stainless and some carbon steels are almost 4 times as strong.

That's an important test, assuming the ring is the weak point.
 

 

[carusoam]

My M20C dropped the roll pin...

It is a springy pin... that loses its springiness over time...

Of course the hole opening up doesn’t help...

 

Important tool to have in your kit... the hex wrench that allows you to remove the radios in your panel... also doubles as the tool that opens the door when the handle falls off...

PP ideas only...

Wait a sec...

So many able bodies on board...

Why did somebody not exit through the emergency exit behind the back seats, then open the door for everyone else?

Not the easiest way out...   just checking to see if that is not considered an available way out....

Best regards,

-a-

[EricJ]

1 minute ago, carusoam said:

Wait a sec...

So many able bodies on board...

Why did somebody not exit through the emergency exit behind the back seats, then open the door for everyone else?

Not the easiest way out...   just checking to see if that is not considered an available way out....

Best regards,

-a-

There's no inside release on the older airplanes.   I had to add one to my early J model.

 

[FlyingDude]

6 minutes ago, EricJ said:

There's no inside release on the older airplanes.   I had to add one to my early J model.

 

How did you add it?

[EricJ]

4 minutes ago, FlyingDude said:

How did you add it?

Pics here:
 

And a very similar version here:
 

 

Edited May 9, 2021 by EricJ

[carusoam]

7 minutes ago, EricJ said:

There's no inside release on the older airplanes.   I had to add one to my early J model.

 

Eric, I’m glad you brought this up...

All Mooneys are able to open the back door... from inside.

Or they can be updated with a small kit to allow People to open the back door rom outside...

 

So...

Check the back door handle from the inside... if unable to open... get the kit from Mooney...

PP thoughts only, not a mechanic...

Best regards,

-a-

[FlyingDude]

I'm sorry man. That must have been awful. But great skill and airmanship. I'm glad you were fine afterwards.

 

[FlyingDude]

Just now, carusoam said:

All Mooneys are able to open the back door... from inside

How? 

[FlyingDude]

Just now, carusoam said:

they can be updated with a small kit

From lasar? As usual? Lol

[EricJ]

Just now, carusoam said:

So...

Check the back door handle from the inside... if unable to open... get the kit from Mooney...

PP thoughts only, not a mechanic...

Best regards,

-a-

The Mooney kit isn't applicable to all airplanes.   Mine was not in the eligible serial numbers so I had to improvise based on previously published alterations.

 

[FastTex]

22 minutes ago, EricJ said:

The Mooney kit isn't applicable to all airplanes.   Mine was not in the eligible serial numbers so I had to improvise based on previously published alterations.

 

That's what I've heard too. Does anyone have one extra handle to sell while I get a new made (somehow...)?

Thanks!

[DV8Pilot]

There’s a service bulletin that addresses this. Might be worth considering just getting this done instead of flushing out a new handle.

https://www.donmaxwell.com/cabin-door-handle-upgrade

 

Edited May 9, 2021 by DV8Pilot

[carusoam]

Cast aluminum Mooney parts of that vintage have known challenges with drilled holes...  see the yokes and related history...

For a spare pre-flown door handle... find @Alan Fox...

Best regards,

-a-

[MikeOH]

5 hours ago, EricJ said:

That's an important test, assuming the ring is the weak point.

 

Bingo!   What do those four small machine screws that hold the tie-down anchor mate with?  Threaded holes in the aluminum spar? steel inserts in the aluminum spar?  Or, a large, well engineered steel plate affixed to the spar?

Strength of the tie-down anchor material may be a very distant second, or third place, in what gives first.

[FastTex]

10 hours ago, DV8Pilot said:

There’s a service bulletin that addresses this. Might be worth considering just getting this done instead of flushing out a new handle.

https://www.donmaxwell.com/cabin-door-handle-upgrade

 

Thanks, I agree. I did a quick search but I cannot find it. I will keep searching but if anyone knows where to get one please let me know.

[RLCarter]

If the roll pin is a loose fit it can be held in place with safety wire, loop it around the bottom of the handle, then run both tails through the roll pin.

[FastTex]

Just now, RLCarter said:

If the roll pin is a loose fit it can be held in place with safety wire, loop it around the bottom of the handle, then run both tails through the roll pin.

I'm afraid I have two issues: the roll pin is broken and the handle has a small crack on one of the holes. I can replace the roll pin and at the same time I'm looking for a permanent solution. Plus my door is really hard to latch. Not sure it is normal...

[Skates97]

When I got my plane I read stories of people having a roll pin falling out of the handle and getting stuck. I put a pair of vice grip pliers in the plane just in case. Then one day someone posted a picture and I realized I didn't have to worry about it. Someone at one point had replaced the roll pin with a cotter pin. It isn't as clean looking as I'm sure a roll pin is, but I have never worried about it falling out and getting stuck. The ends are bent up and around and I don't even notice it.

[Ragsf15e]

Gonna be taking off the door trim, lubing the mechanism and checking the overcenter... and maybe installing a cotter pin with your new door handle?

[FastTex]

4 hours ago, bluehighwayflyer said:

I’ve got a perfectly-sized nail with a large flat head on it in the place of my roll pin.  It has been there for at least 39 years without any issues.  

I think @FastTex’s real trouble, though, is that his door is really hard to latch.  The handle breaking off is only a symptom.  It should not be excessively hard to operate.  

I agree completely. I need to look into the latching mechanism. Has any of you experienced the door opening during take off or flight? It has happened to me because of the stupid pin but I do not know what's the correlation with how strong the latch engages...or should I assume once it latched I'm good to go?