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REAR DOOR HINGES

The stock rear door hinges were in rough shape. Three of them “could” have been salvaged with a ton of work and one was totally gone. So I figured that I would try my hand at fabbing new hinges.

As well as fabbing hinges, I also had to relocate the upper door hinges lower on the tub since the top would be cut off eventually. So I removed the upper door hinge attach plates and welded in a lower position. Once the attach plate was relocated, I cut a slot in the skin for the hinge to slide into for mounting to the tub side.

I planned to use ¼ thick bar stock for the hinge as well as using some tube/pipe that fit some generic hinge pins that I bought. Using a straight edge and along piece of all-thread (with a diameter that matched the hinge pin diameter), I was able to locate the tub side of the hinge and drill and tap the holes to match the mounting holes in the tub.

Once I had the tub portion of the hinge bolted in then I used the all-thread to locate the hinge tube assembly and keep it in line so the door would not bind. I also built an integral stop into the hinge so the door would only open so far. I tacked the pin/tube assy in place and finish the weld on a table.

Then I focused on the inner portion of the hinge... the part that connects to the door. This would need to have a bend in it to make fit the door interface. I figured out the angle needed needed to figure out how to bend the kick on ¼ thick steel. Instead of cutting it in two pieces and welding it, I just sliced it about 60% thru and bent it one a bench vise and a large adjustable wrench. Then I welded up the sliced area.

Right now the hinge pins extend below the hinge bottom and the pins are a fairly tight fit but can be removed relatively easily. Once the build is more complete then I plan on trimming them flush to the hinge bottom and knurling under the pin head to retain the pin.

I also have the rubber closeouts that go around the hinges at the body mate,so that should clean up that area a bit.