Door Hinge Bushes

[v8 fou]

I need to replace the bushes in the door hinges - but I can't find any reference to the job on here.
Could someone please tell me the best way of doing the job? I would guess it would be a case of removing the door with hinges, then removing the beam?
All help gladly received!!

[amarshall]

Good luck! They need to be pressed in and can split if you're unlucky. If it was me, I'D buy a new beam with them already fitted.

[v8 fou]

The beams are in very good condition. I have a machine shop so fitting them should be OK. Just need to know what is the best method for getting at them!

[Jason.goad]

Hello. The usual way would be to remove the window frame, door skin and door beam.
But I suppose, if you had a couple of helpers you might be able to take the door off as 1 large item (it's quite heavy)
Just make sure you mark the hinges before removal to get the alignment correct on replacement.
It can be a bit of a b*gger getting the bolts back through the body.
Electrics would need to be removed the loom is clipped to the beam inside the door.
I found the stainless steel bushes from SJ Sportscar fitted in the beam with just a hand push. The genuine Lotus bushes need a press and as Angus suggested they can crack if rushed.
Make sure the Hinge pins runs freely though the beam after fitting the bushes, I've had to fettle both a genuine Lotus beam and the stainless steel bushes to get the pin through ( just reamed a tiny bit off the bushes with a small flapper wheel.)
Hope that helps

[Hawaiis0]

Just recently done this.
As learnt from Jason above; use freezer bags to hold each piece you dismantle and write details as to where they come from. Step 1 = bag 1 and so on. This way all the spaces should be correct after.
Ident and remove electrics
Window Frame off
Skin off
Mark position of hinge brackets and beam height position at B post with tape
remove hinge pin nuts noting the washers installed top and bottom
loosen one hinge bracket and remove (I did top) but do not pull the bolts out. This kept the spacers in situ
Lift beam off lower bracket
Fettle & reverse build
You are best to use a 14mm reamer (check your pin diameter first) to ensure alignment of the pin through the bushes once you have bedded them into the beam

[Phantasm]

I destroyed a phosphor Bronze bush. I believe one is now copper tubing if not more!!! They are a bear and yes require sanding internally once installed for the door pin to slide through. I used a drill bit with sand paper cone-shaped wrapped/taped around it and increased thickness as I enlarged it. Took a while but got the job done.
If you take the brackets off the frame, you will crack the factory paint and assume the lotus position to get the bolts reinstalled with a heavy door; if you dismantle the door you will have to deal with all the component guts being removed. Neither is a great option, but chances are the door won't align properly once you refit the bushes, and it's easier to adjust the lighter door. Plan for a weekend and you might get it done on time. Also, if you do expose the door beam, suggest you retreat/paint/seal it and the window frame legs as well for future preservation.

[v8 fou]

Sounds like a heap of "fun"! I may ream out the hinges/beam to take thicker bushes if needed.
Can the door be adjusted where it meets the body to compensate for the drop?

[Jason.goad]

You'll have to adjust the hinge to body. There's quite a lot of adjustment available at that point. You'll see when you remove them they are slotted brackets. You should find they go back to the original place and the door has lost the drop. Someone may have adjusted the catch on the b pillar to allow the door to shut properly.