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Unread 12-04-2005, 08:29 PM   #1
EMTimZJ
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Front Door Hinge Fix (10 pics)

So the other day outside the grocery store (really it was ) the wind caught my driver door and I lost my grip. The door flung open with quite a lot of force. Fortunetly I was not parked near any other cars to damage. Nothing happend immediately that day. About a week later I was shutting my door and it would not shut. Futher inspection revealed that the welds had broken on the hinge bracket that is on the door and the hinge bracket was jamming not allowing the door to close.

I had my tools (even my air wrench) with me so I gunned off the bolts, unclipped the wiring harness and worked the the hinge bracket back and forth and it broke off rather easily. I put the door back on only using the top hinge untill I could come up with a solution. (it was 10pm at night and I didn't feel like MacGyvering untill later when I had to.)

So here is the damage with the door off...


Another Shot of the door...


Here is a picture of the hinge bracket...


Hinge bracket after a visit from the angle grinder w/ grinder disk, wire wheel, and 60 grit paper... (psst, always use eye protection!)


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Unread 12-04-2005, 08:29 PM   #2
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Action shot of grinding the door surface...


Damaged area after a visit from angle grinder w/ grinder disk, wire wheel, and 60 grit paper... (don't forget eye protection!)


She sat outside a little bit like this before I realized it was snowing. (I'm sure Woody is a little jelous!)


I got a hold of some 1/8" plate (dimensions in picture are 2.5" x 4") I made a template out of thin cardboard to match the area of the door...


Next, I ground plate to match the template...


Then the plate was welded to the door and then the hinge bracket to the plate. A huge thanks to my friend Craig for helping with the welding. (Yes I know I only have one bolt in, I stripped one while I was trying to put the door on by myself before I drove over to Craig's. It is harder than you think to hold the door and gun the bolts in! Thankfully Blaine could come over and gun the bolts in for me while I held the door in place, Thanks Blaine!)


I'll post some more pictures after I clean the welds up some more and paint it.

Once the door was bolted back up, It was a little high since the extra space was added to the bottom bracket. It still closed fine if I applied a little bit of pressure to the door handle when closing. On the drive home I was thinking of ways to correct this or just live with it. I figured that if I added two washers inbetween the hinge bracket on the door and the bracket on the Jeep it would correct the small difference. As soon as I got home I did it and it works fine.

Sorry for the book!
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Unread 12-04-2005, 08:32 PM   #3
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nice booger welds.
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Unread 12-04-2005, 08:40 PM   #4
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Quote:
Originally Posted by PumaZJ
nice booger welds.
Like I said I am going to clean them up a bit

But hey it worked!
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Unread 12-04-2005, 08:46 PM   #5
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Your tha man, most would have been crying all the way to the stealership
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Unread 12-04-2005, 09:45 PM   #6
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Glad that worked for you Tim! I was unsure of how accurate if was going to be but I'll say I am impressed with your enginering skills!
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Unread 12-04-2005, 09:50 PM   #7
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Quote:
Originally Posted by EMTimZJ
It is harder than you think to hold the door and gun the bolts in! Thankfully Blaine could come over and gun the bolts in for me while I held the door in place, Thanks Blaine!)

Yea too bad I stripped one of them for you... opps... I guess I owe you 13 cents or so... We should have made sure it was all the way lined up before going full bore on the air wrench...
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Unread 12-04-2005, 10:09 PM   #8
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I had that happen to my 93 Limited but it wasn't from the wind but more from a drunk buddy running into my open door while camping. Yea i know very interesting. I took off the whole panel and wiring plug at the door jam and welded a plate on the inside of the door and then welded the hinge back on. It matched up perfectly. You might want to think about cutting off what you welded on and put the plate on the inside and the hinge back where it was so everything matches up perfectly. By the way how didn't you melt the door panel or wiring plug by you welds? Either you had a lot of water on hand or got damn lucky
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Unread 12-04-2005, 10:18 PM   #9
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I've been through this one myself. Fun stuff. Now i'm positive there was a slight engineering fault in that area, its just simply too thin and weak.
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Unread 12-05-2005, 05:27 AM   #10
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Good Job there Tim!!!
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Unread 12-05-2005, 06:08 AM   #11
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Nice clean metal working
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Unread 12-05-2005, 09:58 AM   #12
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Good Job, Thanks for the write up and pictures. I am now enlightened.
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Unread 12-05-2005, 12:04 PM   #13
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Nice safety lessons.


Nicely fixed too.


However, if you need safety glasses for your face, shouldn't you at least cover the leather seats while grinding three feet from them?



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Unread 12-05-2005, 12:16 PM   #14
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Nice work!
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Unread 12-05-2005, 01:30 PM   #15
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Thanks for the comments and suggestions!

Brian, there are often many solutions to a problem. I like the idea of welding to the inside face of the damaged area, good thinking. However, this solution worked as well and was easier to get to for me. You are correct that a lot of heat is generated during the welding, however, no water was needed. (I'll post a better pic later) You can sort of see that the plate is stitch welded to the door. This way not a single long bead was laid (to decrease the heat affected zone) and you can wait a few moments for the area to cool before continuing to the next area. So no wires, plastic or bling bling infinity gold speakers were damaged Also, all welding was done with the door off incase there was any confusion.

Saftey is key! (yeah yeah I know I had the gaurd off of the angle grinder )

Leather smeather! fortunetly I didn't get any burn marks!
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