Ok so I have been waiting to do this for awhile. Really it was trying to source the part for a cheap price without having to buy the whole mirror.
This is going to be an ongoing DIY because I'm in the process of doing it. I'm waiting for the fiberglass to dry right now.
8mm Socket(box end or socket your choice)
Vice(really just convenience)
Phillips Screw Driver
Flat Head Screw Driver
Fiber Glass Kit
Cheap Paint brush
Ok anyways I started out with sourcing this piece.
Again get just this piece if you can, this will make it easier then paying $70+ for a mirror you aren't going to use.
Now that you have your piece start by pulling off the inner mirror cover. It is easy to get off just pull on it, and it will come right off.
Now you grab your 8mm wrench and take off the three nuts. You would think the mirror would just come right off now. Nope your wrong you have to disconnect the mirrors electrical which is inside the door panel. It is held on by a bunch of clips and 3 screws. You have to take all this stuff off to get to them.
Once all that is taken off remove the three screws, and then pop off the door panel. There is one zip tie holding the wires to the door snip it, and your mirror is loose.
This is the part I used the heat gun. I warmed up the seal on the back of the mirror to make it come off easier. You will need it to add to the piece you got if yours didn't come with one like mine.
Time to put your piece in the Vice and start hacking.
You can see the place I started and just went straight down to the bottom. Here is the end product.
Depending on which mirror set you get pre-face lift, or face lift you may have a metal insert that attaches to the plastic. The part I sourced was a facelift mirror piece. The mirrors I have being a 2002 is all plastic. So now another piece in the vise and again some hacking.
This is what I got after the hack saw run.
Alright time to fill that hole we made in the plastic. I used this fiber glass kit because it was cheap and had all the stuff to do it(minus a paint brush).
Ok so now onto cutting out your fiber glass I made mine 5 inches by 3.5 inches which was enough to cover the hole and more on all sides. Ok don't judge my fiber glass job. This was my first time so I'm still learning.
I cut out 8 pieces but only did 4 layers of the weave I was going to do 4 on the back as well, but the mounting posts for the metal piece are kind of in the way so I'll probably just throw some two part epoxy back there to make it strong.
I'm now waiting the 2 hour dry time of the epoxy so I can start sanding then bondo to make the contours, and level that thing out. Actually I have been waiting awhile, and my cure time is now up as i'm finishing up the part one of this. Now back to the garage to continue up the project.