Door hinge instruction help, please

[FLFrank35]

I know I am a bit slow, but the instructions on page 303 are not clear to me. It says, "On just the top male hinges, the outer hole only needs to be tapped." In the picture it looks to me that the inner hole is being tapped. I would consider the outer hole to be away from the hinge end.

Can someone please verify if the picture is correct? Thanks.

135967

[bnelson]

I know I am a bit slow, but the instructions on page 303 are not clear to me. It says, "On just the top male hinges, the outer hole only needs to be tapped." In the picture it looks to me that the inner hole is being tapped. I would consider the outer hole to be away from the hinge end.

Can someone please verify if the picture is correct? Thanks.

135967

They are talking about the hole closest to the hinge pin, or toward the outside of the truck. The picture is correct. I ended up tapping all the holes to make life easier. Made it much easier to install and adjust. I had mine on and off half a dozen times times due to chopping and glassing back together. Paint et.

[FLFrank35]

Oooh:eek:...outside of the truck, not the hinge. And good tip on tapping all of the holes. I'm trying to get a good understanding of the orientation, and how they get installed on the doors/frame.

Thank you!!

[bnelson]

Oooh:eek:...outside of the truck, not the hinge. And good tip on tapping all of the holes. I'm trying to get a good understanding of the orientation, and how they get installed on the doors/frame.

Thank you!!

Yea it was hard for me to wrap my head around it till I actually got them all together. Just remember the hinge pins face forward of the door and it will help.

135993

[FLFrank35]

Yea it was hard for me to wrap my head around it till I actually got them all together. Just remember the hinge pins face forward of the door and it will help.

135993

Thanks for that bit of info! I occasionally refer to the gallery on the FF site but didn't really get a good look at the hinges or pay attention to the handles. I guess one could assume they go either way, so you probably saved me a bunch of head scratching:)

[rponfick]

Welcome to the hardest part of the build, in my humble opinion. I am still letting mine sit in the garage after 6 months, hoping they will install themselves, and I can get back to my life.
Seriously, I would suggest you take them to a machine shop to have them cut to length and all the holes tapped.. After breaking multiple taps in the hinges, and then fretting on how to get the broken part out of the hinge, I took them to a shop that is equipped for that sort of thing.
Also, I welded nuts to the back side of some spots to help in assembly. Had to cut holes in the fiberglass jamb to allow for greater adjustment. Not sure what I will do when I get everything aligned properly, and then tear everything down to paint. Reassembly will not be fun with freshly painted surfaces.
Good luck, Ralph

[Gromit]

I know I am a bit slow, but the instructions on page 303 are not clear to me. It says, "On just the top male hinges, the outer hole only needs to be tapped." In the picture it looks to me that the inner hole is being tapped. I would consider the outer hole to be away from the hinge end.

Can someone please verify if the picture is correct? Thanks.

135967

That is a horrible example of tapping and a good way to break a tap. IMHO a balanced T bar and plenty of lubricant would be recommended.

[FLFrank35]

Welcome to the hardest part of the build, in my humble opinion. I am still letting mine sit in the garage after 6 months, hoping they will install themselves, and I can get back to my life.
Seriously, I would suggest you take them to a machine shop to have them cut to length and all the holes tapped.. After breaking multiple taps in the hinges, and then fretting on how to get the broken part out of the hinge, I took them to a shop that is equipped for that sort of thing.
Also, I welded nuts to the back side of some spots to help in assembly. Had to cut holes in the fiberglass jamb to allow for greater adjustment. Not sure what I will do when I get everything aligned properly, and then tear everything down to paint. Reassembly will not be fun with freshly painted surfaces.
Good luck, Ralph

LOL:D, I know what you mean. This kit is definitely teaching me patience.
Thanks for the tips!

[FLFrank35]

That is a horrible example of tapping and a good way to break a tap. IMHO a balanced T bar and plenty of lubricant would be recommended.

I've never tapped anything. I just bought a new kit with a T-bar.
Thanks for the recommendations!

[VIRGIN MIKE]

Had a machine shop do my hinges; my skills and tools are not up to the precision required to do this perfectly.

[Robodent]

I went over to a buddy’s shop and used his band saw and drill press. I tried with my vise and cordless drill and didn’t get very far. Rob

[FLFrank35]

Had a machine shop do my hinges; my skills and tools are not up to the precision required to do this perfectly.

Hmmmm...that sounds like a better idea.
Thanks

[FLFrank35]

On page 321 it says, "Use a file to square off and make sure the area is flush with the template."
This causes the door hinge to not sit flat on the end of the door. It sticks out about 1/16"

139027

Is this correct? If so, what's the reason for filing it flush with the template and not with the door?
What did everyone else do?

Thanks in advance!
Frank

[bnelson]

On page 321 it says, "Use a file to square off and make sure the area is flush with the template."
This causes the door hinge to not sit flat on the end of the door. It sticks out about 1/16"

139027

Is this correct? If so, what's the reason for filing it flush with the template and not with the door?
What did everyone else do?

Thanks in advance!
Frank

I built up the area where the hinge sits in the jam with fiberglass. I think if I was to do it again I would just make a shim the size of the hinge out of about 3/16 SS and be done with it. But like you are questioning, I think its important that the hinge is flat to surface in the jam. Also I built mine up enough in the jam that there was about 1/8 gap between the hinge and the door skin on the outside so would not chip the paint flexing at that point. I think you can see it if you zoom in on the door picture up above on this post that I sent earlier.

And PS: If you file that part down flush to the jam it gets into where the skin and jam are joined together and makes a hole there. I know this how? You guessed it. I tried that first and created a whole bunch of repair work :(

[rponfick]

I did like bnelson. Built up the jam area with fiberglass. Tried shim, but did not like the way mine fit. You have to do something so that your hinge metal does not force the door fiberglass out on that 1/8 gap. . Had to also add some filler to inside of door to get the large metal support for the hinges to fit flat, and use longer bolts.
Ralph

[FLFrank35]

Thanks for replying, guys! I didn't think allowing the hinge to sit on an angle was a good way to go. And I didn't know whether to file down the fiberglass or build up the hinge area. I think I'll go with some sort of stainless shim under the door-side of the hinge.

Bruce, I zoomed in and see what you did...I like the way you have room all the way around the hinge.

And Ralph, I agree with the longer bolts. I just don't see how the supplied bolts are supposed to work...They're useless! They don't even protrude far enough to screw into the nut plate.

As for the larger T (front 1/2) of the door frame...holy cow! I can only get one or two of the 3 ends to fasten at a time. It's like it goes to a different door/model. I'm not sure how to go about building up the inside of the door:confused: Fiberglass it?

Thanks again,
Frank

[FLFrank35]

A follow-up question...

Is it better to tape the door in place, trim the edges, and then work on the hinges,

or install the hinges and then fit the door, trim the edges?

Thanks,
Frank

[cob427sc]

I taped and fit the door in place, getting the gaps and alignment to work then installed the hinges. Required only modest finishing of gaps once everything was bolted up solid to the hinges, door frame and latch.

[FLFrank35]

I taped and fit the door in place, getting the gaps and alignment to work then installed the hinges. Required only modest finishing of gaps once everything was bolted up solid to the hinges, door frame and latch.

That's a great explanation of how to proceedhttps://thefactoryfiveforum.com/images/icons/icon14.png
Very helpful. Much thanks!