Door side hinges pulled out

[viiking]

I have a really good rust free door from a Typ1 68 which has sustained damage to the door side hinges. The top one has one of the rivet heads come loose from the door body. I assume this isn’t critical as the hinge itself is attached to the support plate inside the door.

Should I give it a small tack weld so that it doesn’t separate any more

The second shows the lower hinge. I had to remove the hinge completely due to other issues. The rivet holes in the door are much bigger than for the head of the original rivet. I am going to replace the rivets with 8mm countersunk screws but the heads will be smaller than the holes.

How do I fix this? Is it a cut and paste a new piece of metal and redrill or should I insert the new bolts and weld the gap closed? Or some other idea?

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1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[infiniteLoop]

What if you put a counter sunk screw through it backwards and welded that in?

[VW_Jimbo]

On the 54, I welded in new steel, then dimpled the metal with a taper head screw. Worked great!
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[viiking]

I gave up on trying to repair it. The metal was too thin so I’m currently grafting in a complete inner rear section complete with the hinge. It should work out ok.

However I tried to get some countersunk screws to fit the upper hinge but these remain too “proud” of the frame. I can’t seem to find M8 countersunk screws which have a narrow enough head angle. The standard M8 bottoms out on the dimpled hole before the top of the head becomes flat.

I don’t think I can enlarge the hole any more than it is as the metal will be too thin and the hinge may pull loose bringing me back to where I started with.

Does anyone have a part number or solution to this so the head of the bolt remains flush like the original rivet? I know I could get it machined but no one is interested in doing a few bolts so I was hoping I could buy something ready made.
_________________
1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[bomberbob]

If you look at the McMaster Carr website, you should be able to find screws that will fit. I think you want to get screws with a different countersink angle. Variables you will need to select are stainless steel versus other alloys, phillips head or torx, screw size and length. With all these variables I can't give you a part number.
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1968 Beetle (storage)
1990 Jetta GLI megasquirted, burning E85 (currently in heavy maintenance)
2004 Jetta turbo GLI
Marion, Iowa

[VW_Jimbo]

Or you can buy rivets. In the classified section there are ads for those rivets. Super easy to install with the door off the car!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[viiking]