From: "Robert Janca" <robert@tabra.com>
To: <fj55@birfield.com>
Subject: [FJ55] Door Hinge Rebuild Tips
Reply-To: fj55@birfield.com
Date: Tue, 13 May 2003 08:05:12 -0700


 I just finished rebuilding my door hinges this past weekend, and so I
thought I would add a few tips to the archive for anyone who needs them in
the future:

1) You can do this by yourself if necessary.

2) As mentioned before, Spectre sells the bushings for FJ-40's and you can
use these to rebuild your hinges.  You can also use the stainless steel pins
they sell, but you will have to cut off the extra length.  I used them and
just cut them off after hammering the new pins in.

3) Use a torch to heat the hinges.  This will contract the pins enough to
drive them out easily.  I did not have a torch handy, so I just set them
directly on the gas stovetop flame for 10 minutes.  I am single, if you are
married, you will meet resistance while attempting this.

3) The hole where the new bushings are to go will likely be worn to an oval
shape.  It is best to replace this, or bore it out and install a sleeve.  I
just used JB Weld to reshape it myself.

4) While you have it apart, check for stress cracks on the door where the
hinges were bolted.  I had to run several beads over stress cracks and then
grind them flush.

5) IMPORTANT:  look carefully at how the top hinges are assembled.  Do not
make the rookie mistake that I made of reassembling them the way that looks
correct.  It is very difficult to pull a pin that has been cut off at the
end.  I had to drill the end of the pin to receive the punch blows needed to
pull it again.

Good Luck!
Robert
ilean rattlesnout
'71 fj55