My truck had an issue when I bought it with the leading edge of the door skin separating. I think this was from the previous owner installing a door seal which was not made for this model of truck; perhaps this post will give folks something to consider when trying to save a buck on new seals.

Here is a pic of the issue:



In this pic you can even see where the separation caused the inner door shell to fall out of the door skin lip:

 

My repair at this point is solid but temporary. I first cleaned up tge paint and rust with a wire wheel on my drill. In this pic, I had already started reseating the skin and the inner shell. I started on top and worked my way down using some gentle coaxing with a crowbar and and extra set if hands which held it together as I worked my way down initially just tacking it.

 

I was able to slowly work my way to the bottom until I had enough tacks to hold it. Once it was all held in place, I extended the beads as much as possible. The door feels much more solid than before the repair.

 

I do want to premise this by pointing out the repair is still not complete. It is solid but temporary. I know better welds are possible and it is not my intention to settle for this although I did get some nice beads put down in the process. I am still just learning to weld. And this was a really tight spot which didn't let me get as close as I would have liked. And there was a bit of paint and rust I couldn't remove. All this accounts for more splatter than I would have liked but its holding solid.

So the next step... Removing the door for better access.

I have heard horror stories involving door realignments so I am hoping to avoid this. The lower hinge has a bit of play in it so a new bushing &/or pin is in order. I figure pulling the door off by removing the pins is the best approach to ensuring an aligned reinstall.

Once I get the door off, I can properly clean up these welds, and lay some more nice beads as needed.

So my questions in all this...

How are the pins removed? It looks as if these are installed and flared which means I cut them.

If the old pins need cut, are replacements available or what advice is there on addressing this issue?

Thanks for any feedback in advance!

 

Here are some hinge pin repair kits... Anyone had luck with these or successfully tried a different method?

Ford Truck DOOR HINGE REBUILD KIT PARTIAL | 22811-2K | NPD

This one is pricey but I was thinking something like this would probably work really well.

http://www.ebay.com/itm/MADE-IN-USA-Door-Hinge-Pin-Bushing-Repair-Kit-FOR-1975-1979-FORD-TRUCK-/330939668350?pt=Motors_Car_Truck_Parts_Accessories&fits=Year%3A1975%7CMake%3AFord&hash=item4d0d8a977e&vxp=mtr

 

Try your local AutoZone type parts store.Find one that carries the "HELP' line by Dorman ,(I think).Their kits are reasonable in price and hopefully head you in the right direction.

 

I work at an AZ, and I believe we do carry the door hinge pins for these old trucks. Thankfully mine doesn't need them yet!

 

Thx... I will stop by and take a look.

 

That damage wasn't from a door seal. That was from letting the door fly open against the travel stop. The door flexes over time and that's what you end up with. The factory only put a few spot welds on there and they tear easily. ....especially next to the hinge like that.

You have it under control, though. Your repair should last a good long time.

 

Check Jerff's Bronco Graveyard for your hinge pins. $9.00 when I got mine in late 2012. Not sure of current price.

 

Well I just noticed this any my OCD is kicking in... I don't know if it was like this before, or if it just occurred... Hope I didn't warp my door.

 

The Bronco Graveyard has a brand new website... Just makes you learn where everything is again though.

They do have the pin but its $9 per pin plus shipping... I think I will stop by the big box store first to see if dorman makes something that will fit; chances are theirs will require cutting but it should be cheap.

I hope the alignment issue is from the pin as there is a fair amount of play in that bottom hinge.


Door Hinge Repair Kit 1973-79-Broncograveyard.com

 

Then there are these which actually look really good but $38 for a pair of bolts?!?! Similar kit & price on ebay... Same plan... Gonna check out pins and bushings at the parts store. Might check out the hardware store as well.

 

Dorman also makes a bushing ASSORTMENT pack with various size copper/bronze? bushings that usually you can make fit if need be. I have even built up worn pins by brazing the worn area on the pin; chuck in a drill press and file 'till back to original non-worn size.A poor mans lathe. Good luck

 

Thanks for the suggestion... It looks like that door sticking out is an alignment issue... I should be able to adjust it out. Already started and am realizing its a pain but must be done... Gonna have to replace the pins before actually finalizing the adjustment.