Technical Doors & Hinged

[Twink80]

This is a bit of a follow on to the thread on doors dropping
That assumed mostly good Integrity of the hinges and mounts
Having been reluctant to take the doors off my car I am now glad I did. 3 out of 4 hinge mounting pads in the doors had fatigue cracks, not suprising as the doors are really heavy!
Top and bottom hinge pads were cracked, the hinge pins were ok but the forged hinge plates were worn from lack of lubrication.
Both are tricky repairs as the steel isnt very thick and you dont want the weld to blow through to the reverse side as this will interfere with the captive sliding mount plate
Here are some photos before and after.
The lower plate repair needed a die grinder to flush back the weld as access is tricky!

 

[Slotman]

Wow, that's good info, thanks for sharing...looks like the repair is going well !

 

[124BC1]

This is a bit of a follow on to the thread on doors dropping
That assumed mostly good Integrity of the hinges and mounts
Having been reluctant to take the doors off my car I am now glad I did. 3 out of 4 hinge mounting pads in the doors had fatigue cracks, not suprising as the doors are really heavy!
Top and bottom hinge pads were cracked, the hinge pins were ok but the forged hinge plates were worn from lack of lubrication.
Both are tricky repairs as the steel isnt very thick and you dont want the weld to blow through to the reverse side as this will interfere with the captive sliding mount plate
Here are some photos before and after.
The lower plate repair needed a die grinder to flush back the weld as access is tricky!

The doors assemblies are heavy on the 124 Coupe also. But is it the door shell or all the bits that are attached to it? I recently found some of my assembly notes from the past.
I had wondered about this when I was about to fit a new door to a Sport Coupe many years ago (when new doors were still available for the Coupe).

So, I weighed the complete door I had removed = 22 kg
I then weighed all the components that have to be fitted to a new door shell (e.g. drop glass, vent window and frame, window regulator, door lock, internal and external lock handles and linkages, window channels, cable tensioner roller, stainless steel trim strips and clips, window winder handle, vapour barrier, all fasteners and check-strap but excluding interior door card and arm-rest) = 10 kg
When the new door shell arrived, I weighed it =12 kg (as expected).

I also weighed some other panels for the 124 Sport Coupe :-
Front wings (fenders), new in primer so no filler, 4 kg each.
Front panel (between front wings) = 3.5 kg
Boot (trunk) lid (the short one on the early 124 Sport) = 7.27 kg bare, + 0.68 kg for the lock, key barrel and trim strip.
Bonnet (hood) incl. sound deadening mat and vent grills = 20.45 kg
Headlight bezels (dual h/l's each side, cast metal type) = 1.82 kg

I also chipped/scraped off all the underseal and all the interior sound deadening (bitumen type) factory applied coating from the interior floor - iirc this filled 3 x 20 litre buckets but unfortunately I didn't weigh them.

 

[Twink80]

The doors assemblies are heavy on the 124 Coupe also. But is it the door shell or all the bits that are attached to it? I recently found some of my assembly notes from the past.
I had wondered about this when I was about to fit a new door to a Sport Coupe many years ago (when new doors were still available for the Coupe).

So, I weighed the complete door I had removed = 22 kg
I then weighed all the components that have to be fitted to a new door shell (e.g. drop glass, vent window and frame, window regulator, door lock, internal and external lock handles and linkages, window channels, cable tensioner roller, stainless steel trim strips and clips, window winder handle, vapour barrier, all fasteners and check-strap but excluding interior door card and arm-rest) = 10 kg
When the new door shell arrived, I weighed it =12 kg (as expected).

I also weighed some other panels for the 124 Sport Coupe :-
Front wings (fenders), new in primer so no filler, 4 kg each.
Front panel (between front wings) = 3.5 kg
Boot (trunk) lid (the short one on the early 124 Sport) = 7.27 kg bare, + 0.68 kg for the lock, key barrel and trim strip.
Bonnet (hood) incl. sound deadening mat and vent grills = 20.45 kg
Headlight bezels (dual h/l's each side, cast metal type) = 1.82 kg

I also chipped/scraped off all the underseal and all the interior sound deadening (bitumen type) factory applied coating from the interior floor - iirc this filled 3 x 20 litre buckets but unfortunately I didn't weigh them.

Great detail
I often wondered about the point in f fitting fibreglass bonnet and boot to the Rally version of the Spider. There can’t be much weight saving for huge expense. The weight difference is likely less than the mud that accumulated under the car of a forest stage.
Its not all about weight uou need strength and stiffness.