cracks in metal around door hinge

[AdrianH]

Not had car long and the drivers door had already dropped. Lower hinge pin very warn so purchased 2 new hinges and bolts with intention of fitting them myself. However on close inspection before starting I noticed cracks around the top door hinge - probably metal fatigue from door slamming flexing the metal. I will need a professional repair now but any advice please on how this should be carried out? I guess its not just a weld up job but strengthening inside of door skin in hinge areas or are new hinge panel inserts available?

[philthehill]

Personally if the door is as badly cracked as you appear to suggest I would be thinking about getting another door - one without the cracking.
Unless you know of someone who could do the welding for you cheaply any welding and repair work is going to cost.
Therefore a S/H door may be the way forward.

[MinorOCD]

Hello Adrian,
Are the cracks in the door or the door post?
I have repaired both, so can give you some idea of what maybe involved.
Also, the door has a check strap (curved steel rod) that stops the door opening too far. This is fixed to the door post with 2 countersunk screws. If you open the door to the limit of the check strap and gently push against it, does the door post flex? If it does, the internal structure of the door post has rusted.
All the best,
Paul.

[MinorOCD]

Hello Adrian,
I re-read your post and noticed you mentioned door skin, so must be the door. Do you have a pic of the crack?
Behind the skin of the hinge mount is quite a heavy structure, made of 1.6mm steel. This usually rusts on the bottom hinge mount, not so much at the top, and even then, is still quite strong.
I think you need to assess how good the door is in total. Most doors will need a lower outer skin and door under door frame repair. Depending on the condition of your door, you maybe able to find a better one, but it is still likely to need the repairs I mentioned.
It’s better to find an original, unrepaired door, that needs this attention so it can be done properly.
My doors had been repaired before, but it was a poor job and I had to unpick that work and start again. The doors never lined up very well, but they do now. The previous repair caused a twist in the door that cannot be adjusted out.
Paul

[philthehill]

Here is the back view of the hinge plate of my seriously lightened drivers door so you can see the strengthening plate arrangements.
All the round holes are the result of removing the welds holding the original internal factory strengthening which was removed as it is not required..

Minor door hinge plate.jpeg (121.73 KiB) Viewed 299 times

[59Elva]

Phil,
Is that aluminum or silver paint on steel?

[philthehill]

That is aluminium paint over phosphate over steel.
From the waist down the interior is aluminium and from the waist up it is matt black.