So, the following are two photos of the passenger side internal door handle release clip, this is the side that did not fail and distort, so I will semi copy this.

[Linked Image]
[Linked Image]
Ordered Delrin bar which should be ok as its fairly hard wearing and can operate within -40 to +120 deg C.

While in the passenger side inner door workings I may have found another " rattle/clunk" there is a medium size multiblock connection that looks like its for the remote locking, its forward in the door and sits on the lower wooden section of door, in my car its totally unsupported and rattles between the door skin and the lower wood door section. Fitted some sound deadening material in the area for it to sit on and restricted its movement.. It will be interesting to see if this stops another low speed rattle..
dave

Dave
Plus Six "Squeak"
Roadster departed.
1936 BSA Empire Star Q8. 1935 BSA W7-35. 1938 BSA M20