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Old 01-18-2014, 05:49 PM
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Need help with dents

Doors, the final frontier. Once I get through these I will be on easy street.

As to how this happened, major front collision hit the drivers fender and damaged cowl, door pillar, door hinges and door. I have the cab square now, cowls replaced, new half door pillar and straight pillar, hinges are soaking and will be rebuilt ( one needs straighting and some welding ) so:

How do I get these dents out and the door straight. I did try pressure and tapping earlier. Maybe I wasn't aggressive enough but nutting moved. Can I heat it and then apply pressure?

Doors are being stripped, glass is coming out as soon as I read the stove bolt
tech tip another 50 times.
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Old 01-18-2014, 06:30 PM
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Here is one hinge, the other is in the same shape. This one has a slight twist in the metal that slides into the door pocket.

Here is the pins I will be using, do I use bushings or just the pins? Whats your experience with bushings?
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Old 01-18-2014, 08:22 PM
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I am currently at work (well at my other job) and cannot enlarge the pictures well enough to give a good plan of attack. However it would appear that the dents are on the jamb part of the door correct? If that's the case it will be tough to get them straight because thats a pretty strong part of the door. You may be able to get to them from the inside once the windows and ahrdware are removed to hammer them out using a piece of bar stock or something to get in there. If that is not an option, you may have to use a little heat to help motivate the metal into seeing things your way. If there is some way you can stblize the doors, you could try welding a tab to them and pulling them out that way as well. I will try to take a better look in the morning when I get home and give more sound advice.

As for the pins and bushings, you will use both to rebuild the hinges. The old pins will press out of the hinges (you may have to grind off one end depending on how they are made) and then youwill see the bushings in the halves once you have them apart. The old bushings can be removed with a tap of a hammer and the new ones can be pressed of tapped (lightly) into place. Change one bushing at a time unless you are sure they are all the same size. Some hinges take 2 different sizes for top and bottom. Hope this random rambling ahs helped in some way.

Kelly
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Old 01-18-2014, 09:49 PM
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Try this pic. Not sure what went wrong with those pics. I tried bar stock and a hammer, nutting. Tried some pressure inside and tapping, nutting. I am going to pull the glass in the morning and get violent with pressure and tapping.

Heat will be the last resort before chopping it out and welding it back.

I am going to try a bottle jack and some wood for pressure from the inside. I think I can pull that off. I am just confused my all spare bars and parts I found
inside the doors. The spare stuff cannot even be for this truck, I have spent hours looking in the shop manual and it just isn't for this truck. GO figure?
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Old 01-19-2014, 05:27 AM
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First off if it were me I wouldnt dream of rebuilding a damaged hinge it'll give you too many problems ...start with nice straight hinges...
The reason you cant get the metal to move on the doors is because theres a few layers there.you wont move it,,replace the door too. you might think your saving money but by the time you give up trying to put a bent door on bent hinges then mounting it and trying to get it adjusted you'll have wasted weeks worth of time and only end up buying another one any way...save yourself some grief and get a good used door and a pair of hinges and be done with it. but use the pins and bushings to rebuild your new (used) hinges dont go aftermarket with these parts you'll really be sorry then...
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Old 01-19-2014, 10:14 AM
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Now that I am home and have gotten a good look at these doors, I agree with DBM. Those could be fixed, but with the time saved in replacing them you would recover the time spent in trying to fix those. Now if you are set on using the doors you have, I would probably cut off the lower part of the door that is damaged and either straighten it after it is off or fab up a new piece. I have to imagine that the outer skin is bent as well since the inside is bent? As for the hinges I apparently missed the part about one of them being bent, again I agree with DBM, and would replace the damaged hinge with a straight one. Put new pins and bushings in and you be ready to go.

Kelly
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Old 01-19-2014, 10:25 AM
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If the hinges are bent, I would seriously be looking for another door. You want SOMETHING right to work with whenever you can. If those hinges are bent, and the door is bent, then the cowl is SURE to be bent too, just buy design they are kinda funky. So if the forces that bent that door also bent the hinges, I am putting a crisp $10 bill on the cowl being bent as well where the hinges mount.

There are a number of sources around here to get decent doors, parts like this are on Craigslist all the time around here. I don't know about where you are at, but I am thinking I would be hunting for another door and hinges. I have some hinges you can have for free if you would like, you pay shipping.

I have a very nice extra door too but it's the other side, and it's a non wing window too, sorry.

Brian
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Old 01-19-2014, 01:53 PM
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The cowls, the entire corner for that matter, has been rebuilt with new cowls,
toe boards, the floor, the works. Also half a pillar, the bottom half, yes it was bent, also rusted out.

Ok, thanks again everyone. I will give it a half day, major heat, bottle jack and my biggest hammer. Then the other half day will be spent forging the fields for
a new door!
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Old 01-19-2014, 03:36 PM
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Success never looked so good!

Never under estimate the power of an impact and fender washers. I need a toggle bolt ( will be sacrificial ) to do the top dent. Stores are all closed today, I will knock that off after work tomorrow.

The lines just fall back into place when I sucked it up with the impact.It is amazing what a guy can do once you give up and go for broke.
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Old 01-21-2014, 04:06 AM
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I gotta admit that does look pretty good...try it , see if it fits and leaves you with some good gaps...
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Old 01-21-2014, 07:34 AM
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You have done an amazing job on that door Craig!

Brian
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Old 01-21-2014, 07:44 AM
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Ditto...Looking good.
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Old 01-21-2014, 05:08 PM
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Wanna job ???
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Old 01-21-2014, 05:30 PM
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As I set here choking on a piece of humble pie, I must admit, I have been around this stuff literally all of my life and I would have never thought of that. Nice job

I hope you don't mind, but that little trick will be filed in my tool box for future reference.

Kelly
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Old 01-21-2014, 06:32 PM
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ok, I got lucky. I have a lot of practise with sheet metal, just not on cars. But it seems to work the same on cars as furnaces, fireplaces and display cases.
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