Further to the good work of Gerry, I found that my window sometimes would not go down when I tried to open the door and I would have to pull the door even though the glass had not dropped to clear the seal and then as the door was open the glass would drop.
I thought this was because I was not using the car very much and the glass was sticking to the seal.
This had been going on for about 12 months, but when you got in the car and closed the door and then re-opened the glass would drop straight away.
Again I thought well I have already dropped the glass therefore its not sticking now.
Also when using the car all day the window would work properly.
Then one day in July the door would not open full stop. The car was in my garage and I could not get to the other door so I just used the key to open all the windows and then pull the lever inside the car to open the door.
I stripped down the door card as per Gerry`s instructions and this it what I found and my solution to the problem.
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The last pic is not to scale and the width of the angle iron is approx. the same as the crappy aluminium bar BMW in their wisdom decided to make it out of. If they had cast it solid it would of been OK.
The screws on the left are SS self tappers (approx. 3.5mm) as there is not a lot of room for the nuts and washers.
The other 3 are M3. When drilling the holes make sure everything is tight together to pull the crack together.
When the left door handle breaks the angle iron picture is flipped. When I get some time I will make a left hand version and drill the left door before
it breaks.
Hope this helps.
Cheers Vic