Door rebuild, beams hinges, frame and window channel lifted

[Silent78]

Finally started rebuilding my drivers side door and it's been a tough job but getting there. I'm about 12 hours in and only starting to put it back together now, everything was rotten and most of the time has been taken up drilling out bolts and cutting the rotten window channel lifter off. But I've enjoyed it mainly thanks to a good friend lending me the use of his lock up. Takes the stress away knowing I can leave it overnight with the door off. Any tips welcome for how I set up the new washers on the door pin. I've got new spacers made up for round the end of the Bush but I'm unsure if I should have a washer on top of the spacers aswell or if I should have a washer on the opposite side with the nut.

[Hawaiis0]

No washer on top looking at the diagrams so that's how I went.

You have a fair way to lift that beam to get the level right.

Did you make some marks before hand?

The centre of the end of the beam where the catch goes should lie adjacent the catch bar striker plate.

From my piccy you can see the guide tape marking the top of the beam level

[Silent78]

I took loads of pictures,
The beams back off, it was only balanced in place, I still need to reattach the nuts on the top bolts but ran out of time. I'm going to fit it tomorrow when I have an extra pair of hands.

[Tanz]

Looks like we are all doing door refurbishment. Hope you don't mind me adding to your thread. Stripped my door down and the beam is fine but frames are a bit rusty where that stupid sponge was against it. Window lift channel was very rusty. Will start putting it back together next week. There is no play in the door hinge but I was going to knock the pin out and re grease it. Can the pin be removed without removing the hinge brackets? I took the nuts off top and bottom but could not knock out the hinge pin. Seemed to be catching on the hinge brackets. At the bottom of the door was a lot of broken glass. There was also broken glass sitting on top of the beam. Think perhaps the quarter light glass has been replaced in the past. Was very difficult to remove from the old door frame - solid with adhesive. A few pictures:

Door beam in good shape.



Window frame not so good



Window lift channel rotten


Door strap spring broken - new one ordered from SJ's

[Hawaiis0]

Pins are waisted and cannot be knocked out. You need to remove one bracket at least. If you do, don't pull the bolts through. Leave them in place to maintain any spacer fittings and just lift off the bracket.

If you do knock em out be prepared for new bushes being required if they drift out.

[Silent78]

As Stu said pins are wasted and can't be knocked through, if only removing one hinge I would be inclined to go with the bottom one as it's easier to access the bolts. Specially if you are on your own. I got mine pretty much finished yesterday, just need to seal round the quarter light and put the door card back on. I ran out of time due to a knew bolt snapping in the door beam, had to drill it out and 're tap the hole but the time I lost screwed me for finishing the job yesterday. Not to worry though as I'll finish sorting it tonight.

[Silent78]

[Silent78]

[Silent78]

One thing I would add is if your fitting a new beam and you have a tap and die set then maybe spent the time using the m6 tap and do all the holes to clear out any powder coating in them. Probably been mentioned before, makes life a lot easier.

[Tanz]

Pins are waisted and cannot be knocked out. You need to remove one bracket at least. If you do, don't pull the bolts through. Leave them in place to maintain any spacer fittings and just lift off the bracket.

If you do knock em out be prepared for new bushes being required if they drift out.

Sounds like if it ain't broke, don't fix it