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Cameltoe & Heel
Barcelona


Joined: 26 Jan 2009
Posts: 1367
Location: Preston - Lancs


PostPosted: Thu Jan 02, 2020 10:36 am    Post subject: Door Hinge renewal Reply with quote

ahoy ahoy Happy New Year all........

Thought I'd post up what I'd been doing as part of my winter maintenance.

I noticed that the drivers door has some play, slight up and down movement with the door slightly open, also I wasn't 100% happy with the fit. I'd already bought new door pins and shims back in spring but decided to defer fitting until winter.

So I cracked on over the Xmas period, you can see new shims in foreground and old ones in the background with one of the old pins, the shims are brass and pretty soft, they were worn as was the pin to a lesser extent.



You can see a new shim inserted, there's four per door, two per hinge, one top one bottom, removing old ones was easy enough with a punch, inserting new ones was easy too.



However installing pins afterwards wasn't, and guess why?, the shims are supplied oversized.



Turns out they require reaming out to 8mm, so onto Amazon for bits.



Using these proved a real pain, access to the bottom hinge is easy enough so can use a drill, the top hinge was not straight forward and needed me to make use of my ratchet and extensions and a UJ. Some huffing and puffing later I git it through and both hinges reamed out to 8mm, pins now inserted perfectly, cleaned and greased the up ready for hanging.



I've now managed to fit the door and all seems well, a few more adjustments on the window and I should be done.

Onto the next one on the list......

Trev
 
  
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decgraham
Barcelona


Joined: 17 Sep 2008
Posts: 1379
Location: Spain


PostPosted: Thu Jan 02, 2020 3:29 pm    Post subject: Reply with quote

Nice work as always Trev Thumb

Happy New Year.

ATB Smile
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1995 993 C2 Cab TipS in Guards Red
 
  
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Cameltoe & Heel
Barcelona


Joined: 26 Jan 2009
Posts: 1367
Location: Preston - Lancs


PostPosted: Thu Jan 02, 2020 4:11 pm    Post subject: Reply with quote

Thanks mate Smile

Oh and BTW whilst I was setting my window height the bloody window regulator decided to sheer a few teeth to make a ruddy horrible knocking noise so just ordered a replacement from eBay.......

Could have been worse I guess, it could have done it after I'd rebuilt the door up frustrated

Anyhow........these damn cars you fix one issue and create another ffs



Trev
 
  
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Zorro
Spa-Francorchamps


Joined: 05 Oct 2014
Posts: 282
Location: East Sussex


PostPosted: Thu Jan 02, 2020 5:54 pm    Post subject: Reply with quote

So what's the purpose of the shims being oversized I wonder.
 
  
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berni29
Indianapolis


Joined: 24 Oct 2009
Posts: 2286
Location: Kent


PostPosted: Thu Jan 02, 2020 6:28 pm    Post subject: Reply with quote

Hi

You mean that the shims are sold undersize, and you ream to size, in this case 8mm?

I hope that's not the case, as I quite fancy replacing mine having read your post.

My car is a high miler so probably need it.

Berni
_________________
993 C2 Tip 1994 187k miles. Black and Grey. M029 & Bilstein HD's, Elephant Racing RS bushes F&R, RS mounts, strengthened engine carrier, 100 cell cat inserts, HID's. Solid steering arms mod, top of the engine rebuilt, mapped by Wayne, suspension set up by Chris.
 
  
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Cameltoe & Heel
Barcelona


Joined: 26 Jan 2009
Posts: 1367
Location: Preston - Lancs


PostPosted: Fri Jan 03, 2020 8:44 am    Post subject: Reply with quote

berni29 wrote:
Hi

You mean that the shims are sold undersize, and you ream to size, in this case 8mm?

I hope that's not the case, as I quite fancy replacing mine having read your post.

My car is a high miler so probably need it.

Berni


Hi Berni, oversize/undersize depends how you look at Smile, so yeh essentially there's too much material to get the door pin through so has to be removed with a 8mm ream bit, it could be because the hinge may not hold the shims in perfect alignment so the drilling will help achieve this.

Yes if you car is high mileage then yes it's likely to have play in the drivers door hinges, just open the door slightly and lift it. Mine has 104k, the passenger side is ok so I'm likely to be leaving that one Smile.

Trev
 
  
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berni29
Indianapolis


Joined: 24 Oct 2009
Posts: 2286
Location: Kent


PostPosted: Fri Jan 03, 2020 11:20 am    Post subject: Reply with quote

Hi

That seems a little strange. If it is an alignment issue then once fitted they would need to be line bored with both in situ like an engine block to maintain the alignment. If they are too small for the pin then are undersize Smile. If are too big for the mounting hole then are oversize, I think that is the way it works.

I will have to investigate. And yes will check the play in mine. I guess you do not have any play now on the drivers door?

Thanks!

Berni
_________________
993 C2 Tip 1994 187k miles. Black and Grey. M029 & Bilstein HD's, Elephant Racing RS bushes F&R, RS mounts, strengthened engine carrier, 100 cell cat inserts, HID's. Solid steering arms mod, top of the engine rebuilt, mapped by Wayne, suspension set up by Chris.
 
  
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Cameltoe & Heel
Barcelona


Joined: 26 Jan 2009
Posts: 1367
Location: Preston - Lancs


PostPosted: Tue Jan 07, 2020 12:02 pm    Post subject: Reply with quote

Berni, yes the two shims have to be in situ and you drive the remaining bit through both shims so that they're perfectly aligned.

Now no play at all in the drivers door.

I've also now replaced the window regulator with the second hand eBay item which works perfectly.

Trev
 
  
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pietrzj
Spa-Francorchamps


Joined: 19 Mar 2014
Posts: 287



PostPosted: Thu Jan 09, 2020 9:02 pm    Post subject: Reply with quote

Trev,

Are you sure you had to reem out to 8mm?

I sort of did this job a year or so ago. With the door in situ. The bottom pins went through the shim (aka bush). Extreemly difficult, but did it. The top hinge was more difficult and as I snapped a modified G-clamp I have had to leave the top pin 3/4 of the way in, but again the pin went through the lower shims/bushes. Pins Bushes were genuine Porsche.

Modifying a stronger G-clamp to finish it off at some point when I can face the job.

I probably said in my other post that I did the job as going over bumps I noticed a knocking and I thought it was suspension related, but it turned out to be the door moving on the slack bushes.
 



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Marky911
Sepang


Joined: 04 Jun 2009
Posts: 2827



PostPosted: Thu Jan 09, 2020 9:17 pm    Post subject: Reply with quote

Good thread. Great little project.
Definitely worth reaming them out for that perfect fit. Thumb

It’s funny now I’ve seen this, I remember viewing one or two air-cooled cars over the years that had their hinge pins half sticking out.
They must have been done by folk who lacked that bit of finesse and a reamer. Wink


Pietrzj comments “Are you sure you had to ream out the bushes?” ...
Followed by a photo of a snapped G clamp....
Followed by “I’ve had to leave one pin only 3/4 of the way in.

Floor

I like your style Pietrzj. I like your style. Thumb
 
  
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Pretzel
Hockenheim


Joined: 20 Apr 2014
Posts: 704
Location: Bedfordshire


PostPosted: Thu Jan 09, 2020 10:56 pm    Post subject: Reply with quote

I'm a little confused, is it possible to replace the bushes and pins (including reaming to size) without removing the door?
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Cameltoe & Heel
Barcelona


Joined: 26 Jan 2009
Posts: 1367
Location: Preston - Lancs


PostPosted: Fri Jan 10, 2020 8:36 am    Post subject: Reply with quote

So you definitely have to take the door off or how could you put the new shims into the hinge Dont know

Yes, I was at the same point trying to get a new door pin through a new shim (without reaming) and no chance, it would go so far and stop completely, even with force, decided to google at that point and up it came, a need to ream the new shims to make them fit.

The pins are always sat slightly proud anyway, they don't drive in all the way, about 8-10mm.

Still crying laughing at the broken G clamp btw Floor

Trev
 
  
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Pretzel
Hockenheim


Joined: 20 Apr 2014
Posts: 704
Location: Bedfordshire


PostPosted: Fri Jan 10, 2020 4:45 pm    Post subject: Reply with quote

Cameltoe & Heel wrote:
So you definitely have to take the door off or how could you put the new shims into the hinge Dont know


Reading pietrzj's post he indicates bushes/pins were replaced in situ. I wondered if the door could be supported fully open while carrying out the replacement.
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Cameltoe & Heel
Barcelona


Joined: 26 Jan 2009
Posts: 1367
Location: Preston - Lancs


PostPosted: Mon Jan 13, 2020 8:45 am    Post subject: Reply with quote

I see what you're saying here but if the door is off at both hinge points then isn't by virtue off the car?. If you did this you would need to remove the door arrester pin and it would leave the electrical rubber hose attached to the door. You would need to hold it vertically very close to the car and work on it from there.

Trev
 
  
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pietrzj
Spa-Francorchamps


Joined: 19 Mar 2014
Posts: 287



PostPosted: Wed Jan 22, 2020 8:09 pm    Post subject: Reply with quote

I created a wooden fram for my door so I could do it without undoing the bolts. The frame supported the door so I could remove the pins and replace them and the sleeves. I only had a few inches to play around in as a result. But it meant I could do it solo.

I will see if I can dig out some photos.
 
  
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pietrzj
Spa-Francorchamps


Joined: 19 Mar 2014
Posts: 287



PostPosted: Wed Jan 22, 2020 9:17 pm    Post subject: Reply with quote

And yes, The door arrestor pin was removed. I mounted the wooden frame on a set of wheels so I could fully open the door.
 



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pietrzj
Spa-Francorchamps


Joined: 19 Mar 2014
Posts: 287



PostPosted: Wed Jan 22, 2020 9:21 pm    Post subject: Reply with quote

All for the sake of not damaging the paint on the door hinge bolts and the worry about not lining the door up properly on the re-fit. Looking back I am not sure it was worth the hassle, but I wasn't in a hurry at the time.
 



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pietrzj
Spa-Francorchamps


Joined: 19 Mar 2014
Posts: 287



PostPosted: Wed Jan 22, 2020 10:52 pm    Post subject: Reply with quote

one of the easier parts of the job...
 



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pietrzj
Spa-Francorchamps


Joined: 19 Mar 2014
Posts: 287



PostPosted: Wed Jan 22, 2020 10:55 pm    Post subject: Reply with quote

but I did have to modify the bottom end of the clamp by drilling holes through at different angles so I could turn gradually with a small alan key.

The trouble I go to to save a few bucks
 
  
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Cameltoe & Heel
Barcelona


Joined: 26 Jan 2009
Posts: 1367
Location: Preston - Lancs


PostPosted: Fri Jan 24, 2020 9:15 am    Post subject: Reply with quote

Ha ha brilliant effort right there loving the way you secured the door Smile

Trev
 
  
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