Door hinge repair....

[Chaz]

Driver door makes loud pop sound when opening or closing. Took a closer look and it looks like the lower single bolt on the upper hinge.....door side not truck side...the bolt hole is cracked around and the metal is flexing a lot....anyone have this happen? Any easy fix? Pull the door off and weld around the hole? Or buy a replacement door.....? I really dont want to buy another door cuz i know its not gonna match and my truck looks bad enough as it is......

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[Chaz]

Another pic

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[Chaz]

Oh and i like my doors......theres no hole in the bottom where everybody likes to put speakers......

 

[Frankenchevy]

I’d say pull it and weld it, but also find the cause. Might be binding or alignment differences between top and bottom hinge or something else altogether...maybe just age

 

[legopnuematic]

If you do weld them, be sure to drill out the ends of the cracks and if possible to open up the cracks a little, so then the weld will penetrate and not get ground off, leading to it cracking again.

 

[PrairieDrifter]

My 77's passenger door is almost just like that.

 

[Snoots]

Driver door makes loud pop sound when opening or closing. Took a closer look and it looks like the lower single bolt on the upper hinge.....door side not truck side...the bolt hole is cracked around and the metal is flexing a lot....anyone have this happen? Any easy fix? Pull the door off and weld around the hole? Or buy a replacement door.....? I really dont want to buy another door cuz i know its not gonna match and my truck looks bad enough as it is......

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Frankenchevy and legopnuematic are pros here. Just be certain to keep track of any shims. Also check the latch. You may need a piece of pex there.

 

[Chaz]

Well think i found the problem.....frickin hinge was broke....the connector piece holding the top and bottom of the hinge is just gone......wonder how that happened the door been working fine for years lol....

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[Chaz]

The cut hinge pin was done by me for removal.......im not referin to hinge pin....heres another pic of hinge after removal........

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[Chaz]

So looks like all the torque from the hinge spring went into the lower half of the hinge.....single bolt....causing excessive strain on the door hinge mount where it broke.....instead of dispersing the torque across the entire hinge assembly and 3 mounting bolts

 

[Chaz]

Note regarding hinge pin replacement.......hinge pins must be pressed in with a press.....i tried and failed with big hammer and even a vice.....