Here's how you can approach undoing shaved door handles on your 1997 S-10, whether it's a standard extended cab or one with a third door:
1. Assessing the Shaving Job:
* Quality of the Fill: The success of your restoration depends heavily on how well the handles were originally shaved. A poorly done job will be more challenging to repair. Look for cracks, imperfections, and inconsistencies in the paint.
* Type of Filler: Body filler is common, but other materials might have been used. Knowing this will help determine the best removal method.
* Paint Matching: You'll almost certainly need to repaint the area after removing the filler, so consider having some extra paint mixed to match your truck's original color.
2. Removing the Filler:
* Careful Grinding: This is the most common method. Use a rotary tool (Dremel with various sanding attachments) or an electric sander with progressively finer grits of sandpaper (starting with coarse, then moving to fine) to carefully remove the filler. Work slowly and patiently to avoid damaging the surrounding paint or metal. Go slow and check frequently for the original door handle cavity.
* Chemical Strippers: Some specialized paint strippers might work, but they risk damaging the surrounding paint and the truck's body. This is generally a less preferred method due to the risk of damage.
* Heat Gun: A heat gun can soften the filler, but use extreme caution to avoid damaging the paint and underlying metal. This method is risky and should only be attempted by someone experienced.
3. Repairing the Holes:
Once the filler is removed, you'll likely have significant holes where the door handles used to be. You'll need to repair these before installing new handles:
* Metal Patching (Ideal): If the holes are large or irregular, consider using sheet metal to create patches and weld them in place. This is the most robust solution but requires welding skills.
* Body Filler (For Smaller Imperfections): For smaller holes, you can use body filler to fill the gaps, sand it smooth, and prime/paint the area.
4. Installing New Door Handles:
* Source Replacement Handles: Find replacement door handles for your 1997 S-10. You can find these online, at auto parts stores, or at junkyards.
* Installation: Follow the instructions that come with your new handles. This usually involves drilling new holes (if necessary, in the positions revealed after removing the filler), and attaching the handles securely with bolts or rivets.
Important Considerations:
* Professional Help: If you're not comfortable with bodywork and repairs, consider taking your truck to a professional auto body shop. This will ensure the best results and avoid potential damage.
* Patience and Precision: Undoing shaved door handles is a time-consuming process that requires patience and attention to detail.
Remember to always prioritize safety when using power tools. Wear appropriate safety gear, including eye protection, gloves, and a dust mask.
