Discussion
Just got back in from a quick drive, struggled to open the passenger door. This has not been a problem before, suddenly the door opens and drops. Open the bonnet and a hole has appeared in the body where the top door hinge fits to such an extent that I can see the bolt. If I let it, the door hinge would drop straight out of the bodywork. 
Anyone had this problem before, what are the chances of being able to repair myself.
Anyone had this problem before, what are the chances of being able to repair myself.
Any chance of a pic?
I did this guide to pictures on photobucket, there are other photo sites but I use this and I like it cos its easy.
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
It sounds like the hinge has come out of the body - it will need fibreglassing back in which while its not fun I think will be possible.
You'll need someone to hold the door while its open, get inside the door and undo the bottom hinge - I haven't done it but I think its just a bolt. You'll need to undo the check strap aswell then take the door off.
(Might be easier if you have the door supported with something aswell - it will get heavy!)
You'll also need to remove any wiring (speaker, maybe central locking if it is fitted).
There will be some more posts below who will know whats involved better than me but if you are reasonably practical I think you will be able to mend it yourself.
I'd certainly have a go at it if it was mine.
You can get a fibreglassing kit from Halfords or other car accessory shops.
It's a messy experience so don't wear your sunday best and your hands will itch for a bit afterwards.
The kit has glass fibre mat which you cut to shape and stick down with the resin supplied then you stipple lots more resin into the mat. The resin is like treacle. You build up the fibreglass in layers, its very strong when its done, though its more of an artistic sculpturing experience than a car repair!
It doesn't smell too great either, and the resin gets quite warm as it cures which is normal.
Chris
I did this guide to pictures on photobucket, there are other photo sites but I use this and I like it cos its easy.
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
It sounds like the hinge has come out of the body - it will need fibreglassing back in which while its not fun I think will be possible.
You'll need someone to hold the door while its open, get inside the door and undo the bottom hinge - I haven't done it but I think its just a bolt. You'll need to undo the check strap aswell then take the door off.
(Might be easier if you have the door supported with something aswell - it will get heavy!)
You'll also need to remove any wiring (speaker, maybe central locking if it is fitted).
There will be some more posts below who will know whats involved better than me but if you are reasonably practical I think you will be able to mend it yourself.
I'd certainly have a go at it if it was mine.
You can get a fibreglassing kit from Halfords or other car accessory shops.
It's a messy experience so don't wear your sunday best and your hands will itch for a bit afterwards.
The kit has glass fibre mat which you cut to shape and stick down with the resin supplied then you stipple lots more resin into the mat. The resin is like treacle. You build up the fibreglass in layers, its very strong when its done, though its more of an artistic sculpturing experience than a car repair!
It doesn't smell too great either, and the resin gets quite warm as it cures which is normal.
Chris
Edited by Barkychoc on Friday 4th July 20:32
When you try to take the door panel off you should take the speaker out first then, working through the speaker hole, there may be one or two small bolts from the back of the armrest through the inner door skin to remove before the panel will pull off. When the bottom hinge plate is revealed there are three bolts, the middle one goes through into the pivot in the sill, the other two are to move the adjustment plate in the bottom of the door. So it is the middle one you need to unscrew. The arrangement in the top of the door is the same. What has almost certainly happened is that the pivot bolt has seized in the pivot boss inserted in the g.r.p. body and as the door has been tight to open it has gradually forced the boss to rip out of the grp. The problem is to get a good 'hold' for the new grp in the hole and against the boss AND get the boss in correct alignment. DONT get penetrating oil anywhere near where you want to g.r.p.! It isnt a 5 minute job if you want to do it well. Once you have the door off and you know what you are facing, preferably with a picture, then post again and we might be able to give you some more experience.
Heres some pictures
Looks as if the nut can easily be relocated in the original position, so that is good news. It looks like it is only a sort of resin that held it in place. Not sure if this is just the resin that you get with glassfibre kits or if you can get a resin on its own.
Looks as if the nut can easily be relocated in the original position, so that is good news. It looks like it is only a sort of resin that held it in place. Not sure if this is just the resin that you get with glassfibre kits or if you can get a resin on its own.
Edited by geoffn on Saturday 5th July 16:26
Edited by geoffn on Saturday 5th July 16:49
Edited by geoffn on Saturday 5th July 17:00
That pink resin looking stuff looks like Isopon P40 - its chopped fibreglass mat mixed with resin in a tin, you mix hardener with it. I suspect if thats the case it may have been repaired before.
You can get it from halfords.
http://www.halfords.com/webapp/wcs/stores/servlet/...
They do a bigger size aswell.
Chris
You can get it from halfords.
http://www.halfords.com/webapp/wcs/stores/servlet/...
They do a bigger size aswell.
Chris
Unfortunately that pink stuff looks like unreinforced body filler, which simply isnt suitable, and as Chris says it has been repaired before. If you repair it with filler it is now almost certain to break out again, and pretty quickly. I am afraid I have to advise you to cut out all the pink stuff and get back to clean, original g.r.p. You need a rough surface of the original glassfibre to bond to, and you need the brass bush to be completely clean (and of course free again on the bolt!). Then you need a proper glass reinforced plastic mix, i.e. resin mixed with hardener PLUS glassfibre chopped strand to reinforce it. You might get away with Fibrefil or similar but I wouldnt risk it as it looks like quite a big hole. It is quite a tricky job holding the bush in exactly the right place and moulding the mix in place at the same time. We have done it using two pieces of threaded bar and a tube to line the top and bottom bushes up and hold the top bush in the right place until the resin sets.
I'm making this up as I go along but you could try putting a bit of mat round the nut with a cable tie then making the base of it flat(ish) to sit under that hole (cut into it with scissors so it looks like a top hat).
Then put more mat over the gaps.
Once the initial resin has set cut the cabletie off and apply more resin and mat.
Its going to be really infuriating however you do it - and you may end up breaking it out and starting again more than once.
Good luck, its really easy this armchair fibreglassing business!
Then put more mat over the gaps.
Once the initial resin has set cut the cabletie off and apply more resin and mat.
Its going to be really infuriating however you do it - and you may end up breaking it out and starting again more than once.
Good luck, its really easy this armchair fibreglassing business!
geoffn said:
Gerald-TVR said:
I live in Droitwich/Worcestershire how far away are you?
Norman, I am just west of WolverhamptonHi Geoff, you'r right, no chance in the rain! As you wont be doing this for a few days I wont post immediately but can I suggest you contact me using the email link from 'members', then I will give you a phone number and try to discuss all the options with you. You can certainly use the door as a good guide, with certain precautions.
Yes Chris, I have worked with g.r.p. quite a bit, I used to be heavily in to kayakking, making them and breaking them! For those who know what I mean, the smell of curing g.r.p. resin was the closest to glue sniffing I ever got! In addition my son works for a classic car firm who have had to do a couple of TVR's with this door hinge issue, you are certainly note alone Geoff.
Yes Chris, I have worked with g.r.p. quite a bit, I used to be heavily in to kayakking, making them and breaking them! For those who know what I mean, the smell of curing g.r.p. resin was the closest to glue sniffing I ever got! In addition my son works for a classic car firm who have had to do a couple of TVR's with this door hinge issue, you are certainly note alone Geoff.
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