Does anyone have any ideas on how to repair the splines on a manual window regulator? The PO has destroyed both sides with pliers or vice grips. The regulators work fine but the handles won't work because the splines are gone. Any ideas will be helpful, Thanks.

 

Are you referring to the gear like protrusion that the handle clips to? I'm not sure there is a way to "repair" that splined shaft. You may need to replace the unit with a new one.
National Parts Depot has all the door internals in the door hardware section:
http://npd.dirxion.com/WebProject.as...Code=car09flx#

 

Yeah the splined shaft that the handle clips to, I have found some repair kits for some old fords that has a new shaft and some rivets but nothing for camaros. I dont think there is going to be a way to repair the splines themselves but maybe a kit to replace just the shaft or another way to attach the handle to the shaft. I thought about drilling a hole in the shaft and the handle and putting a cotter pin through it but theres not much room to work.

 

They do make aftermarket handles that have an allen setscrew to hold the handle to the shaft, but still need some splines to grab the handle even then.
You could drill and tap the center of the shaft for 10-24 NC thread, then drill the handle and install a screw to hold the handle. Not real clean, but might get you by for awhile.
The replacement regulator is #C10782-7A pass side, or #C10782-8A driver side. $85 ea. at NPD.

 

Those are some good ideas 1971BB427. I didn't want to go all out on new parts just yet I am working on the drivetrain now I will get to the interior later but for now this is what I ended up doing.

This is what I started out with

I drilled an 1/8th inch hole in the shaft.


I drilled a matching hole in the handle. I chose 1/8th inch because that was the size that matched the cotter pin I used. The handle was missing so I bought a new steel handle. I made sure I got steel so it would stand up.



This is what I ended up with. It was kinda a pain to get the cotter pin in but it went in and it works great there is no slop in the handle and the window goes up and down. The best part the only thing I had to buy was the new handle.

 

That's a simple fix that should hold for awhile!

 

Pretty good temp fix. I can't recall which of my old cars it was on, but I remember having a window crank with a tapered pin to hold it on. The recessed cup behind the handle would keep it in place. A cotter pin isn't hardened so it won't last forever, but maybe for as long as you need it to. You could always do a simple power window conversion:
http://www.youtube.com/watch?v=jF89i0IWPiU

 

Red Green is my hero, that is a sweet power window setup, Thanks Camaro 69. I know that the cotter pin is fairly soft, so it won't last but hopefully I will not have to change it out all the time.