Hi Eric,
I had a similar problem, the lower hinge mounting inside the door was a
real mess. In my case, I figured the door was toast, and was going to have
to be replaced (didn't know you could get repair panels). Anyway, since I'd
pretty much given up hope on the door, I figured I had nothing to lose in
trying to fix it. I cut a square away from the skin about 1 foot each side
(started cuts with a cut-off wheel, finished them with a sawzall). This
gave me good access to the back of the hinge area. I hammered the area back
straight, welded the cracks back together, and then welded in a bunch of
re-enforcement panels. Sprayed in a healthy wallop of rustoleum before
welding the (original) skin panel back on. It's roughed out with fiberglass
re-enfoced bondo right now, but I'm pretty sure I can get the skin looking
OK. I still haven't sorted all the problems out with the door, but it's a
*LOT* better than it was before. I can't imagine that pulling the entire
skin off would be any easier.
One tough part was trying to figure out a way to clamp the skin panel back
on for welding (I ended up using magnets while I got the welds started)
The lower hinge takes a lot of abuse- mostly in compression. I would guess
(from the wear/damage I've seen) that it actually takes a worse beating than
the upper.
Anybody had experience with the fiberglass doors? I'm guessing they're a
lot lighter, and a lot easier on the hinges. Also, any experience with the
roll-pans from "eastcoastcustoms.com"- considering their ZR roll panel at
about $250 including all the lighting and harness.
Feeling your pain-
Ryan.
55 2nd 3100.
-----Original Message-----
From: varanus@mail.phoenix.net
[mailto:varanus@mail.phoenix.net]
Sent: Thursday, May 20, 1999 7:08 AM
To: oletrucks@autox.team.net
Subject: [oletrucks] 57 door panel hinge repair
Hi: ya'll may remember that I asked some questions re the
repair
panel for the 57 hinge pocket in the door column (right
above the
step pocket). The stress imposed on the actual door hinge
mounting
plate from the rusted hinge pocket may neccessitate
replacing the
"block" that the lower hinge mounts to in the door (right
behind the
lower door hinge access panel).
Chevy Duty sells these repair panels. Unfortunately, to
access this
spot, the door must be taken apart. My door is in pretty
much
excellent condition. I hate to think of taking the door
apart. What
do ya'll think about this? The mounting block has been
"ripped" away
from it's original position. I am no welder but it seems to
me that
if the block was pounded back into place and the metal rips
welded,
then that may be an option. It seems that most of the
weight is on
the upper hinge. I don't want to do a half assed job nor do
I want
the problem to re-surface in the future. But I hate to take
the door
apart.
My lack of experience with metal working makes these types
of jobs
seem more complex then maybe they really are. Perhaps, if I
were
familiar with welding, I would have more of a "no big deal"
approach.
What do ya'll think? And, what do you think the best
approach would
be if I were to disassemble the door? Cut a square around
the
damaged area? Take the entire door apart?
Thanks, Eric Pesci
oletrucks is devoted to Chevy and GM trucks built between
1941 and 1959
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