OK.. I am refitting my drivers door. There is sufficient sag for the door to hit the bottom runner when closing..

When the door is closed, the profile, hinge positions etc look fine..

I have traced the problem to too much play in the top hinge.. Even when fully tightened there is a lot of play..

The problem appears to be the the top hinge plate (body side) has a cracked weld and is flexing under the load of the door etc..

How do I fix this?.. I have no welding gear.. What trade would I go to?

Thanks

[Edited on 26-2-2005 by StenGuns]

I guess I could purchase a little mig welder.. Last welding I did was as an apprentice bolier maker about 26 years ago.. Lasted about 6 weeks (too much dirt).. Boy, I loved the gas axe though!..

I had this problem. I read up on this at http://www.vw-resource.com.  They suggest two solutions. Firstly shimming the bottom hinge to correct for the sag. The second solution is to jack up the corner of the door to try and bend it back into shape. I tried the second one and it seemed to work a little bit.

Thanks..
Not sure about the second idea but the first idea has given me some thought.. Instead of shimming the bottom hinge.. Maybe I could shave the top hinge by .5mm? That would pull it up nicely! Still would like to get the crack welded though..

the crack will only get worse if it isn't repaired now,
you'll end up forever trying to componsate for it .
maybe you could hire a welder some do on site

There must be an aussie vee dubber welder in Your area...
I get My Son to do My welding even though I have a welder..

MIG Welders are very good value...
You would probably find many uses for it...
You may have to get someone to show You how to set it up..
My Son has done welding courses but He lent His MIG Welder to someone who knew what He was doing and now it works better than it ever did before....

so sometimes it pays to lend things.....

After You do the welding, You need to put some fish oil on the back section so it won't rust....
I'm guessing that You will paint the weld on this side....

Lee

All valuable help.. Thanks.. No time to go back to school to weld.. Rather pay someone how can do it (a better job) in a fraction of the time

Just waiting for some paint to dry so here is what I did..

First shot is the rust on the pillar around the bottom hinge.. I have blown it with rust converter and fish oil.. then clean filled and painted.. Hopefully it will hold.. This hinge bracket wasn't so bad.. just the rust holes warned me to do something now!

Then.. for the top hinge, I have shaved about .3mm off the hinge.. Also I couldn't wait to get it welded (this can still happen after blue slip) so I drilled a pilot hole through the door post and through the hinge bracket.. Counter sunk a little then drove a self tapping machine screw through both pieces.. It tightened it up beautifully.. Finally ground the screw head back to allow clearance..

Here's hoping

You little f%#king beauty.. It closes with the slightest push of a finger.. That feels so good I'm off to the club for a beer!!

[Edited on 27-2-2005 by StenGuns]

[Edited on 27-2-2005 by StenGuns]

Would you believe the rangers turned up!.. Someone complained about the noise!.. Thats two beers now!

OK.. Had one beer and decided to remove the passenger door.. Here are some shots of the bottom channel.. Good grief!! I can repair for a while but definately needs a new door!!

Cleaned and blown with rust converter

Filled and sanded

Primed

Painted and back on the bug

Both doors are swinging beautifuly.. I am rooted.. time for dinner and a bottle of red!!

Love a days work with good results!!

Which Rustconverter did you use?