The Lotus Grand Tourers

Re drill... I used a battery powered Ryobi drill and didnt have a problem. Did you rem
Unfasten the check strap... care not to open door too far if you do.

Thanks. I'll check whether my battery drill will squeeze through the gap or unfasten the check strap (carefully).

After a lot of other jobs got in the way I used Sunday afternoon to do this. Undid the check strap bolt, drilled and tapped M6 and installed a grease nipple in the waisted section of the pin. Pumped in a bunch of grease and the door is back in line and very smooth.

Just took my door off to check for hinge pin collar wear and have very little wear evident! Looks like it might have just been a loose lower hinge bracket

Door off, so shot up to LB got a hinge kit. Seemed to be massively oversized. Bushes no way going over pin. rubbed down the pins until the bushes slid on and off. Cleaned up the bush tube with a dremel. Got the pin half way in and nadged the threads then got it stuck. Nadged the pin and bush trying to sort out.

Before I cough up another £50 quid what is the consensus on slack - pin to bush? The old pin I can feel the small amount of play but it rotates beautifully.

Use the old one or hit the streets with my handbag?

Is a hinge kit comprised of new bushes and a new hinge pin? If so I would have thought you would press the bushes into the door beam and then ream them to suit the pin, using a suitable pilot to ensure in-line reaming. I have a few adjustable reamers - may have one to suit. Sounds like handbag time!

Pete