The (black-art) of Door Hanging

I've hung Cortina doors before and I don't remember having too much trouble. However, I've spent weeks, on-and-off, trying to fit the passenger door on my 2-door Super.

In desperation I recruited the help of my son, David, who normally has no interest in cars. I struggled for another half hour and got it "sort-of" right. Then I had a bright idea (everyone has one once in their lifetime) to use two 4-inch chisels to locate the door.

Using two chisels to support the door, and manoeuvre it into the correct position, relative to the door frame.

The photo shows what to do, but here's the blow by blow account:

1) Fit the hinges to the door. Note there are packing pieces (like sheets of sandpaper) which go between the hinges and the A-post. There are NO packing pieces between the hinges and the door. Tighten the nuts on the door just enough to hold the hinges in place. NOTE:- My striker plates on the B-post were NOT fitted at the time of fitting the door.!

2) Offer the complete door into the door-frame, making sure the 6 studs from the hinges are located in the holes in the A-post. Ensure the packing pieces (sandpaper bits) haven't dropped off! It helps if the window is wound down for this exercise!

3) Get your son, daughter, or a n other to sit inside the car, armed with a ratchet, six inch extension piece and a 1/2 inch socket. For extra comfort, remove the seat! It can be done with the seat in position, but a few minutes will remove the seat.

4) Get your son, daughter or a n other to place the metal plates over the studs. They seem to only go on one way, so you may have to fiddle around to get them on. Get ONE nut onto one of the top studs, and one onto the bottom. Do not tighten them yet.

5) Place two chisels under the door, with the sharp end of the chisels resting on the sill. It helps to have a third person to tell you which way the door needs to move, relative to the door frame, although we managed with just two of us. Manoeuvre the door with the chisels. When it's in the right place, get your assistant to tighten the two nuts.

6) Open and close the door, and check the gaps. Try to get the same gap all round. Once you are happy with the position of the door, now adjust the door inwards and outwards, relative to the door frame, by moving the door relative to the the hinges ON THE DOOR. When completely happy, tighten up all the nuts, six on the A-post, two inside the door on the top hinge, two on the outside of the door on the top hinge, and three inside the door on the bottom hinge. 

As you tighten up each one in turn, keep checking the door hasn't moved, by opening and closing it.

After that, its relatively easy to fit the striker plate to the B-post. The door should open without breaking your thumb on the push-button, and should not open once closed. You don't want it opening the first time you go round a roundabout!!! The door should shut with a nice, satisfying "clunk". Check that the door opens using the internal door-opening lever too.

Some other things to note:-

A) The hinges may not feel worn until you fit them to the car. The weight of the door will soon show up wear in the hinges. You'll be very lucky if there is no wear in your hinges!

B) Don't trap either your own, or your assistant's fingers in the door!

C) You need to remove the trim panel to gain access to the A-post nuts.

D) Your assistant may need to be told in detail what to do. Questions like "Which way do you turn to tighten?" need polite replies. Instructions like, "Nip is up until its just tight" may not be understood.

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Story written:- 09 May, 2005