How to fix driver's door hinge - pics - JeepForum.com

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post #1 of 21 Old 10-19-2006, 10:08 PM Thread Starter
Kornik
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How to fix driver's door hinge - pics

Finaly it's time to fix my door's hinge. I took out the fender to properly align them and here is what I saw:









The question is - how to fix it the best way? I assume simply welding it aroung may be not eunoght, but the metal above and below the hinge place looks like sheet of paper :-(


92 XJ Laredo Mods: bored TB, 3" lift, 1-ton steering
93 ZJ Limited Mods: bored TB, K&N insert, e-fan; prothane bushings, NP242J, 3" lift, 1-ton steering; Atlas winch

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post #2 of 21 Old 10-19-2006, 11:05 PM
joe2feathers
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time to go doorless....dam thats nasty lookin ...good luck

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post #3 of 21 Old 10-19-2006, 11:13 PM
AZ Jeff
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The way a pro at a body shop would do this is as follows:

1. remove door hinge from door
2. clean old sheet metal off body side of hinge
3. cut out jagged hole in body, and weld in new flat panel in the area (probably of heavier guage than original
4. reinstall hinge on door, and weld body side to newly installed panel
5. paint, and reinstall fender

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I don't own an XJ any longer, but I still think they are the best of all the Jeep products ever made. My XJ was my favorite vehicle in my 50+ years of driving.
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post #4 of 21 Old 10-19-2006, 11:15 PM
xj BMX xj
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wow your wors off than i am my hinges we allredy welded on once by the PO he did it rong and *****ed up evry thing..... id say just tack it in place to see if ligns up straight then weld as much as you can of the hing back on the just ad some steel around it to help brace it

*edit* or doo what he said

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post #5 of 21 Old 10-20-2006, 06:39 AM Thread Starter
Kornik
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Quote:
Originally Posted by joe2feathers
time to go doorless....dam thats nasty lookin ...good luck
I can't - it's my DD :-) at least untill I buy ZJ

92 XJ Laredo Mods: bored TB, 3" lift, 1-ton steering
93 ZJ Limited Mods: bored TB, K&N insert, e-fan; prothane bushings, NP242J, 3" lift, 1-ton steering; Atlas winch

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post #6 of 21 Old 10-20-2006, 06:44 AM Thread Starter
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Quote:
Originally Posted by AZ Jeff
The way a pro at a body shop would do this is as follows:

1. remove door hinge from door
Already done as you can see in the pictures - actually I was thinking about taking the door off too, but I'm a little affraid if I'll be able to align it back toegether - now the lower hinge is stabilizing everything.
Quote:
Originally Posted by AZ Jeff
2. clean old sheet metal off body side of hinge
3. cut out jagged hole in body, and weld in new flat panel in the area (probably of heavier guage than original
And here is the problem - the pilar panel to which the hinge is welded to is somehow deeper then the rest of the pilar - so I think I have to put this new piece of steel underneath... We'll see.

92 XJ Laredo Mods: bored TB, 3" lift, 1-ton steering
93 ZJ Limited Mods: bored TB, K&N insert, e-fan; prothane bushings, NP242J, 3" lift, 1-ton steering; Atlas winch

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post #7 of 21 Old 10-20-2006, 07:57 AM
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If you can get a peice of heavier gauge steel in behind it, or cut the entire damaged section out and just replace it, that would be your best bet to fix it right.
Will

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post #8 of 21 Old 10-20-2006, 08:16 AM
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Keep the door attached to the hinge. Make sure the bottom hinge is still attached to the door also. With the door shut, it should be fairly well lined up. Then you do your welding. Should have no alignment problems that way.

Aaron
1999 XJ @ 6 on TSL 35s w/ Aussie D44 & XRC8
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post #9 of 21 Old 10-20-2006, 09:12 AM Thread Starter
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Quote:
Originally Posted by Power5
Keep the door attached to the hinge. Make sure the bottom hinge is still attached to the door also. With the door shut, it should be fairly well lined up. Then you do your welding. Should have no alignment problems that way.
That's the plan - I'll try to put some steel beyond the hole and weld everything through making some kind of sandwitch - steel plate, pilar, hinge.

One more thing - what do you guys think about drilling one or two bores in center of the hinge and weld it through them too?

BTW. I'm surprised how it's is screewed - such a heavy hing is literaly spot weldet to such a thin steel :-(

92 XJ Laredo Mods: bored TB, 3" lift, 1-ton steering
93 ZJ Limited Mods: bored TB, K&N insert, e-fan; prothane bushings, NP242J, 3" lift, 1-ton steering; Atlas winch

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post #10 of 21 Old 10-20-2006, 09:40 AM
jcaddyer
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This is definitly an XJ problem. My XJ needs some welding around that door hinge. My sister in-laws XJ looks like yours.
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post #11 of 21 Old 10-20-2006, 09:49 AM
AZ Jeff
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Quote:
Originally Posted by Kornik
That's the plan - I'll try to put some steel beyond the hole and weld everything through making some kind of sandwitch - steel plate, pilar, hinge.

One more thing - what do you guys think about drilling one or two bores in center of the hinge and weld it through them too?

BTW. I'm surprised how it's is screewed - such a heavy hing is literaly spot weldet to such a thin steel :-(
The way to reweld the door hinge so it does not tear out again is to use base metal on the body that is thicker than OEM. This means cutting out the entire area of thin metal where the old hinge welds were, and welding in (so it's in the same plane as the original metal) new, THICKER metal. The weld line for this thicker metal is considerably outside the line where the hinge joins the pillar, thereby spreading the load out over a broader area of the pillar.

If this method is done, then boring holes inside wont' be necessary, nor beneficial.

AZ-Jeff
I don't own an XJ any longer, but I still think they are the best of all the Jeep products ever made. My XJ was my favorite vehicle in my 50+ years of driving.
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post #12 of 21 Old 10-20-2006, 01:01 PM
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Quote:
Originally Posted by xj BMX xj
wow your wors off than i am my hinges we allredy welded on once by the PO he did it rong and *****ed up evry thing..... id say just tack it in place to see if ligns up straight then weld as much as you can of the hing back on the just ad some steel around it to help brace it

*edit* or doo what he said
Mine has the same problem. The hinge came off and the PO took it to a shop and they welded it on crooked. Now there's a big gap between the fender and the front of the driver's door; the back of the driver's door touches the rear door. There's also a gap at the top of the door and it leaks when it rains.

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post #13 of 21 Old 10-20-2006, 01:30 PM
xj BMX xj
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Quote:
Originally Posted by SteelersFan745
Mine has the same problem. The hinge came off and the PO took it to a shop and they welded it on crooked. Now there's a big gap between the fender and the front of the driver's door; the back of the driver's door touches the rear door. There's also a gap at the top of the door and it leaks when it rains.
mine smacks the jeep since mines 2 door. but it starting to rust there now so i guess I'm gonna have a black spot there since i dint want there to be bare metal exposed through the winer

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post #14 of 21 Old 10-20-2006, 01:43 PM
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i had mine welded.
Previous owner took advantage of the dealership fixing it the first time, and the fix held on both doors... but i did something stupid...
i was backing out of the driveway, had the door slightly open, and it cought the corner of my mom's van, which snapped one weld and pushed the door into the fender damaging both.

My mechanic welded and did the body work for me when he was doing the bodywork on the rear from the wreck.

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post #15 of 21 Old 10-20-2006, 02:30 PM
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Tacking does not work it needs a good solid weld at least a couple times. I paid the body shop 70 bucks to put mine back on and it still has a crack but it doesn't drop down like it used to because it was about to fall off. I dunno why our Xj's door keep wanting to fall off.
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