Door hinge repair, advice needed
 

The usual problems on the driver door. Hinges are worn out.

Problem with this one is that former owners have done some hillbilly repair without bushings and just filled the hole with very thin sheet metal making it wear even more.
Door is out a bit and makes a lot of wind noise when driving.

Today I started to take it apart to fix it.
Removed the door and found that the bracket on the body wasn't worn to bad. I was prepared to cut them of and weld on new pieces. But as it looks that might not be needed.
I was thinking that I just could weld on some material on the outer part of the hole and grind it to fit properly. When I place the bushing in the lower hole it just move a little bit outward. The upper bushing makes a little resistance when pressing it in to the hole. that one might need a small amount of filler with the weld but might be OK as is.

So do you think it would be enough to fill the gap with the MIG-welder or go the whole way and make a new bracket.

The lower hinge is OK, just need new bushings
https://cimg8.ibsrv.net/gimg/blazerf...68e8711187.jpg
https://cimg1.ibsrv.net/gimg/blazerf...8680d5d4b9.jpg

Another option:

https://blazerforum.com/forum/paint-...stalled-89003/


George

I'm not sure that will work since the hole is oval for the big bushing on the top hinge.

I found them on Amazon but it would take at least two weeks for them to arrive to me here in Sweden.

10-4. I don't have any experience going the welding route but it seems reasonable, I don't know much about the hardness and brittleness of the resulting weld and how hard it would be to drill or shape a round hole in the correct position. Worth a try though because all new hinges has the opportunity for many more issues.

George

I thought I once saw a factory repair hinge kit where the welds between the original hinge and door were broken off and a replacement was installed with bolts.

I'm on my phone so this is the most info I can provide at the moment.

If it was me I would get a steel spacer that has the correct OD for the oversize hole and weld or silver braze it in place. You can size the ID to fit the hinge bushings.

I have welded the holes to make them smaller and then used an air die grinder to open them back up to fit a standard bushing. Its not hard if you are comfortable doing it that way.

I am.curious, how do you make sure the new holes are in the correct location?

Usually only half of the hole is worn and needs to be welded. I'd say I'm just that good lol but its Usually luck.

:icon_lolsign: