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cef911f1 Samba Member
Joined: May 20, 2012 Posts: 5 Location: Rock Hill, SC
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Posted: Thu Jul 24, 2014 1:14 pm Post subject: DIY Door Hinge Pin Removal Tool |
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Recently, I decided that I wanted to add a right side rearview mirror. In order to do this I had to remove the existing door hinge pin to replace it with one with the threaded mirror mount. Of course to do that, I first had to get the old hinge pin out. I also had to e careful not to damage the paint on the door!
There was a member selling a tool on The Samba but it was rather pricey for what I hoped to be a onetime use. Being an Engineer, I decided to make my own inexpensive tool for the job.
Tools - required
Vise
Drill with right angle attachment and drill bit set (up to 5/16” dia.)
Vise
Hack saw
Flat file
Epoxy
Tools – optional
Drill press
Grinder
Extra-long drill bit set
Material
Harbor Freight 8” C-Clamp
Short piece of ½” EMT Conduit (2” long)
5/16”Dia. x 1-3/4” Dowel Pin (or a sacrificial 5/16” dill bit)
Unfortunately, I didn’t take step by step photos of how I built this but I think there are enough pictures that you shouldn’t have any trouble replicating what I did.
I started with an 8” Harbor Freight C Clamp (Item#39610, $6.99 on sale). I clamped the C-Clamp in my vise and unscrewed it until the swivel pad popped off the ball. I then unscrewed it the rest of the way out.
In my case I was able to clamp up the C-Clamp in a floor standing drill press and using an extra-long drill bit, drill a 5/16” dia. hole in the clamp face in line with the threaded hole. It’s best to start small and work up to the 5/16” diameter. (I’m sure 1/4” dia. would be sufficient but I chose 5/16: (.3125) as it is just under the 8 mm pin dia. (.318)) I drilled the hole approximately 3/8” deep. I happened to have a set of extra-long drill bits. However, this could also be accomplished using a hand drill with a right angle attachment with the C-Clamp held in a vise.
I then inserted the 5/16 dowel pin in the hole. Since the drilled hole was a little oversize, I used epoxy to hold the pin in place. If you can’t find a dowel pin, you can cut off an old drill bit and use it.
After the epoxy set up, I cut away the outer portion of the C-Clamp’s pad. See picture. Using my bench grinder, I then shaped the end leaving about a 1/16” of material around the outer side of the dowel pin.
Next, I screwed the threaded rod back into the C-Clamp with a 2”long piece of 1/2” EMT conduit over the dowel pin. I screwed the threaded rod in until it forced its way into the conduit. (You might want to peen the end of the conduit a bit to close it in so that when the ball pops in, the conduit will stay on the ball.)
This tool worked great for removing the upper hinge pin and I think would work for the lower if the running board was removed.
Link to Imgur album: http://imgur.com/a/pAD4q
Last edited by cef911f1 on Tue Jul 29, 2014 1:19 pm; edited 1 time in total |
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Digger89L Samba Member
Joined: May 16, 2013 Posts: 1130 Location: Western Canada (SK)
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Posted: Thu Jul 24, 2014 3:57 pm Post subject: |
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How much pressure is actually involved in pressing one of these pins out? The reason I ask is because I've broken one of these large C clamps just clamping a couple of 2 X 4's together ...the clamps are made of relatively low-strength cast iron, so I'm surprised that the epoxied area didn't just break off once the pressure was applied to it .... Or, am I missing something here??? |
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grandpa pete Samba Member
Joined: July 06, 2008 Posts: 6426 Location: St. Petersburg, FL
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offshores Samba Member
Joined: February 08, 2012 Posts: 1085 Location: So Cal
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Posted: Thu Jul 24, 2014 4:21 pm Post subject: |
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Great little DIY tool you have there. You wanna sell it? |
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cef911f1 Samba Member
Joined: May 20, 2012 Posts: 5 Location: Rock Hill, SC
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Posted: Tue Jul 29, 2014 1:17 pm Post subject: |
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Not really. It would probably cost more to ship than it did to make.
Besides, I have a whole collection of shop made tools that I've built over the years. This is the only one for a VW (so far) but I have several for Porsches, Mini's, MBs, Triumphs and a few of my friends' cars.
Building a body rotisserie now. Doing a frame off on a TR6. |
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smkn_vw Samba Member
Joined: August 22, 2004 Posts: 809
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Posted: Tue Jul 29, 2014 5:57 pm Post subject: |
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cef911f1,
Great tool thanks for posting it, I actually need one now. I'm going to make one but have a question, was it difficult to turn the c-clamp by hand to remove the door pin? If so, maybe I can weld a nut to the end and use a ratchet but don't know if that material is weldable. If it wasn't difficult to turn I say forget the welding. _________________ "So didja?" -Bob Hoover |
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bladerunner80 Samba Member
Joined: February 13, 2011 Posts: 255 Location: Fife, WA
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Posted: Wed Jul 30, 2014 9:26 am Post subject: |
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I tried making a similar tool based off some other threads I found, but once I really torqued it down, the c-clamp began to flex and I worried it was going to break. You can buy super heavy duty clamps, but I decided to a different route. I posted a video a couple weeks ago of a guy using his bench vise to push the pin out, and once I got everything aligned, it worked like a charm. It takes a of force to push those pins out and the vise method gives you more leverage and clamping force.
Here is the thread to how I removed my pins - http://www.thesamba.com/vw/forum/viewtopic.php?t=601346&highlight= _________________ http://das-auto-66vw.tumblr.com/ |
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smkn_vw Samba Member
Joined: August 22, 2004 Posts: 809
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Posted: Wed Jul 30, 2014 10:42 am Post subject: |
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Hey blade, I think I remember seeing the video you're talking about actually been couple lately. I was hoping to do it without having to remove the doors. I have to do both doors because drivers side mirror was jb welded to a stripped pin so I'm going to do that side right and add a mirror to the other door. At least now I have plan A and B haha maybe C if I have to rent the tool and pay shipping but rather throw that money in the gas tank and go cruising. _________________ "So didja?" -Bob Hoover |
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crvc Samba Member
Joined: April 28, 2004 Posts: 1308
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Posted: Wed Jul 30, 2014 11:47 am Post subject: |
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I made a similar tool for removing the pins on my '67 door. But couldn't get the c-clamp to budge it. Then I put the entire door in the vise...and broke the vise when using a cheater bar to turn it. Then took the door to a machine shop that got them out and drilled for new pins with threads for rear view mirrors.
crvc |
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cef911f1 Samba Member
Joined: May 20, 2012 Posts: 5 Location: Rock Hill, SC
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Posted: Fri Aug 01, 2014 6:12 pm Post subject: |
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smkn_vw wrote: |
cef911f1,
Great tool thanks for posting it, I actually need one now. I'm going to make one but have a question, was it difficult to turn the c-clamp by hand to remove the door pin? If so, maybe I can weld a nut to the end and use a ratchet but don't know if that material is weldable. If it wasn't difficult to turn I say forget the welding. |
I had nowhere near the difficulties that the other commenters did. I didn't have any problem turning the clamp. As for welding a nut on that end of the threaded rod that should be possible. Before I went to that much trouble, I'd just put a cheater piece of pipe of the rod. |
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johnnypan Samba Member
Joined: October 24, 2007 Posts: 7431 Location: sackamenna
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Posted: Fri Aug 01, 2014 7:18 pm Post subject: |
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Other than the fact you cant develop the force to remove most door pins its fine. |
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tb03830 Samba Member
Joined: December 02, 2009 Posts: 1045 Location: Leavenworth, KS
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Posted: Thu Dec 21, 2017 9:34 am Post subject: |
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grandpa pete wrote: |
Clever ; thanks for sharing
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How does that work on the bottom hinge. I can see the top hinge working but the turn handle will hit the door and you turn it and grind against the door surface if it lines up at all. _________________ "Sic Vic Pacem, Para bellum - Pray for peace, prepare for war."
1964 Convertible Bug - 1600cc SP engine with a stock H30/31 Carb and SVDA Distributor - Swing Arm Highway Flyer Tranny, Gene Berg's Temperature Dipstick, 2.5" drop spindles, 2" narrowed adjustable front end. Chromed OEM fan tower. |
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bugheadred Samba Member
Joined: January 23, 2003 Posts: 666
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Old duck Samba Member
Joined: June 22, 2018 Posts: 2 Location: Kansas
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Posted: Wed Oct 03, 2018 3:02 pm Post subject: Re: DIY Door Hinge Pin Removal Tool |
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Nice idea, all went well until I added a couple hard turns, then I heard a pop and low and behold, that harbor frieght clamp broke right in the middle. Found a vintage, forged clamp on eBay and I will try it when it gets here. I think the concept will work with the right clamp. In the mean time I will keep soaking it with pb blaster. |
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klroger Samba Member
Joined: September 22, 2017 Posts: 150 Location: deep river, Ottawa Valley
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Posted: Wed Oct 03, 2018 5:18 pm Post subject: Re: DIY Door Hinge Pin Removal Tool |
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I've always used my air hammer. It has rattled out any pins I've had to remove. Cut a hole in the finger of a glove to cover the air hammer & punch & it won't damage paint.... You can do it right on the car!!!!!
Roger _________________ I Didn't know what to do, So I Didn't do anything!!!! |
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Old duck Samba Member
Joined: June 22, 2018 Posts: 2 Location: Kansas
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Posted: Thu Oct 04, 2018 11:59 am Post subject: Re: DIY Door Hinge Pin Removal Tool |
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Well, after messing around with the clamps etc., I hooked up the air hammer and in a matter of minutes the pin was out!! One short burst and the pin was up a half an inch and loose.... A couple firm taps with a hammer and punch and out it came after 50 years in the hinge. Easy peasy. |
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FL-Frank Samba Member
Joined: August 08, 2015 Posts: 823 Location: Jupiter, Florida
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Posted: Sat Oct 20, 2018 9:31 am Post subject: Re: DIY Door Hinge Pin Removal Tool |
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Has anyone tried this pin removal tool?
https://www.ebay.com/itm/283188353230
Pros/Cons? _________________ “Tinker Toy” 1967 Savannah Beige Beetle Sedan...........Mostly Original Survivor
“Fritz” 1964 Gulf Blue Karmann Ghia Coupe...Complete Pan-Off Restoration SOLD |
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andk5591 Samba Member
Joined: August 29, 2005 Posts: 16757 Location: State College, PA
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Posted: Sat Oct 20, 2018 12:19 pm Post subject: Re: DIY Door Hinge Pin Removal Tool |
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Curious myself. I have an Eastwood and had the bolt head machined down to a smaller size and it works, but that one looks nice. _________________ D-Dubya Manx clone - 63 Short pan,1914.
Rosie 65 bug - My mostly stock daily driver.
Woodie 69 VW woodie (Hot VWs 7/12).
"John's car" 64 VW woodie - The first ever
Maxine 61 Cal-look bug - Cindy's daily driver.
Max - 73 standard Beetle hearse project - For sale
66 bug project - Real patina & Suby conversion
There's more, but not keeping them... |
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FL-Frank Samba Member
Joined: August 08, 2015 Posts: 823 Location: Jupiter, Florida
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Posted: Sat Oct 20, 2018 3:06 pm Post subject: Re: DIY Door Hinge Pin Removal Tool |
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I think I’ll buy one of these and see how it does.
Looks like the door might have to come off first to be able to access the bottom hinge pin though??? _________________ “Tinker Toy” 1967 Savannah Beige Beetle Sedan...........Mostly Original Survivor
“Fritz” 1964 Gulf Blue Karmann Ghia Coupe...Complete Pan-Off Restoration SOLD |
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FL-Frank Samba Member
Joined: August 08, 2015 Posts: 823 Location: Jupiter, Florida
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Posted: Mon Oct 22, 2018 12:43 pm Post subject: Re: DIY Door Hinge Pin Removal Tool |
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FL-Frank wrote: |
I think I’ll buy one of these and see how it does.
Looks like the door might have to come off first to be able to access the bottom hinge pin though??? |
The tool arrived today, and As I thought, either the running board or the door needs to come off first for the required clearance to fit the tool on the bottom hinges. Although it just barely fits on the top hinges with the doors still on the car, there is extremely little clearance between the door and the tool which will definitely result in damaged paint as the tools press bolt is turned.
_________________ “Tinker Toy” 1967 Savannah Beige Beetle Sedan...........Mostly Original Survivor
“Fritz” 1964 Gulf Blue Karmann Ghia Coupe...Complete Pan-Off Restoration SOLD |
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