The Stovebolt Site Forums The Shop Area Paint and Body Shop Doors Door Hinge problem

I broke three bolts off the hinge that attaches to the door sill on my 42, The reason they broke is because the thread on the bolts that penetrate all the way through the hinge and stick out the other side of the hinge had rusted threads and no way could they come out.
I removed the door by knocking out the hinge pins.
That half hinge wouldn't come out no matter how much I tried to force it.
What I did was to use the cutting disk to make two 1/16" wide horizontal cuts 2" long across the door fram at the upper and lower ends of the hinge and levered back the material inside the cuts, to expose the hinge slot.
With a big Stanley screwdriver, I prised up the metal both sides of the hinge big enoough to pull the hinge out.
After locating a hinge off of a spare door, I made sure the new hinge and its bolts ran freely and gave it a bath of Lanolin-based pressure pack anti-rust.
After I screwed in the three retaining bolts, I straightened the metal tab back to where it should be and neatly welded up the cuts with a Henrob gas torch on low settings to complete the job successfully and without a blemish to the door frame.
I'd tried drilling the broken bolts out before, but that takes hours, an Easyout won't work too good either because the rusted threads were so rusted they were enlarged in diameter..
My way worked for me.
I wouldn't advise welding the hinge on to the cab. The door frame pressed metal is thin, welding would heat and soften it and over time, the hinge and the metal beneath it would tear away. There's no place to go after that.
Good luck mate,
Zacca