Mid-90s Mazda Miata...
Mid-90s Mazda Miata exterior door handles are normally mounted horizontally, but Paul turned this Miata handle 90 degrees, allowing it to be mounted in the lower portion of the door. This is a much lower mounting point than the original Ford handle, providing easier access from ground level. Plus, this position allows the door handle and linkage to coexist with the Specialty Power Windows assembly.
You can see how some of the...
You can see how some of the Miata door-skin is welded into a cutout on the cabover door. Miata door handles come from the factory with chrome-plating, and the center portion operates quite easily with one finger. This one may stay chrome-plated, or it can be painted (or powdercoated) to match the exterior paint. The chrome offers a little bright detail to the cab.
The inner handle and locking...
The inner handle and locking mechanism is anodized graphite/black and is mounted in the original (horizontal) position in the inner door-panel.
If youve ever installed...
If youve ever installed a Specialty Power Windows assembly, you might wonder how this one is located in the lower portion of the door. Paul swapped the scissor-operated mechanisms left for right to the opposite door. They work just as well, and this also provides more room for the Mazda door handles. You can also see how a paint pen was employed to record dimensions on the inner panel. Remember to measure everything twice before cutting metal or drilling any holes.
At this point the passenger...
At this point the passenger door has a working handle and window mechanism. Theres still room to install the window glass and cover the inner panel with a stock cover plate. The vertical lines are bracket centers for the window mechanism.
Paul started the installation...
Paul started the installation with a complete Mazda Miata doorall the small screws, washers, and interior hardware will be needed before the job is complete. Paul marked a perimeter around the exterior handle where the Mazda steel will be welded to the Ford steel. The size of the rectangle isnt of much importanceexcept to create a clean edge to weld.
Here are the doorjamb latch...
Here are the doorjamb latch mechanisms.
The inner handle has a pair...
The inner handle has a pair of rods that will connect to a pivoting bellcrank at the outer edge of the door panel. One rod operates the latch; the other operates the door lock. Both rods will run from the handle to the pivoting bellcrank, and from the bellcrank to the doorjamb latch mechanism.
Paul measures the approximate...
Paul measures the approximate length of the rods that will operate the doorjamb latch. He even recessed the area around the bellcrank mounting screw to allow the door panel to mount flush.
Its important that you...
Its important that you understand how each part of the latch operates in conjunction with the other partsand how the rods push or pull the triggers of the latch and also the inner and outer handles.
Examine the wear spots to...
Examine the wear spots to see how a part rotates to push or pull a rod, or stop an actionas with the locking mechanism. Some minor modifications to these parts may be necessary to allow the locking mechanisms to operate properly.
Pivot points are critical...
Pivot points are critical to the locking direction and the distance the rods need to travel. These need to be studied to design the shape of the bellcrank and the distances to the hole centers.
In order to rotate the exterior...
In order to rotate the exterior door handle position, Paul created a pivoting bellcrank for each door to operate the inner handle locking mechanism. The new bellcrank works in tandem with the stock Mazda bellcrank. This drawing shows how it has two ears with holes to accept the latch rod and the lock rod.
The pivoting bellcrank is...
The pivoting bellcrank is mounted high in the dooralmost horizontal with the inner handle. A small access hole was cut in the doorjamb to allow mounting tools. The two bellcranks should operate the rods without interfering with each other. They can change the operation of the rods from push-to-pull or from lock- to-unlock.
Heres the location of...
Heres the location of the latch and locking mechanism mounted in the lower portion of the doorjamb. A hole was cut that matched the nylon insulation of the Mazda mechanism. White lithium grease covers the moving parts of the mechanisms.
The jamb catch is mounted...
The jamb catch is mounted securely to the opening side of the doorjamb. Very little adjustment is possible when this item is securely mounted. Its important to make sure it will function properly with the striker plate mounted inside the door.
These two nylon-retaining...
These two nylon-retaining pins are stock Miata parts that help secure the rods to a point inside the door panel where they wont interfere with the operation of the window mechanism.
Paul created a paper template...
Paul created a paper template of the latch mechanism thats mounted inside the door panel. Some doorjamb material was cut out and filed to the precise shape of the template to promote an accurate interface between the latch and jamb-striker mounted to the doorjamb. Note the recessed screw-heads.
With perforated Masonite mounted...
With perforated Masonite mounted in the door in place of the glass, the operation of the power window mechanism and door latch can be evaluated without any danger of breaking the one-piece door-glass. Clearances may need to be fine-tuned, as each installation is inherently different.
Door handles are one of the most often used elements of any vehicle, and how well they work is rarely noticed until they dont work well. While we were at Wheelers Speed Shop in Huntington Beach, California, we witnessed a 48 Ford COE truck getting a complete upgrade, from its drivetrain to all of its mechanical components. When we spotted the Mazda Miata door handles, we couldnt resist checking out how they operated. The outside door handles had been turned 90 degrees in the door panel, but that fact didnt change the smooth functioning of the mechanisms inside and out.
The inside pull-type handle (also taken from a Miata) was mounted in the center of the interior panels in the original position. A small bellcrank was added to the system between the rods that lift the latch, but the mechanical operation of the stock Mazda mechanism didnt suffer as a result.
Although the thought of adding Japanese componentry to classic iron may not appeal to some, consider that the Miata handles were designed to be compact and to have a classic appearanceprecisely the criteria many of us seek for our own projects. Check out these photos to see if a Miata door handle mechanism might make a neat custom addition to your ride.