Bent Door

[BillM]

My door frame got tweaked during a high wind event so I need to remove it for repair (2010 Eagle). Does anyone know what size rivets 4Wheel uses on the hinges?

 

[fish more]

Call FWC, give them your serial number

 

[BillM]

I drilled out the rivets from the door side of the hinge and removed the door. The door is made with a foam core bonded to an inner and outer skin. The aluminum frame is attached at each corner with 2 screws into a piece of aluminum angle. The frame in between the corners is bonded to the skins. The adhesive on my door failed near the top hinge allowing the frame to bend and tweak the hinge also. This made it very difficult to close the door as I had to push the door toward the top hinge and up to close it.

I think I'm going to remove an inch or so of the foam from the hinge side and replace it with a piece of wood that is glued and screwed to the skins. This will give me a solid structure to attach the frame and hinges to. This pic is of the hinge side of the door with the frame removed.

 

[BillM]

Made a hot wire foam cutter to remove 1.25" of foam from the hinge side of the door. The tool is just a U shaped piece of wire clamped between two pieces of wood and heated with a propane torch. It worked great but if anybody tries this be sure to do it outdoors and avoid breathing the fumes. Cut a piece of wood to replace the foam and glued and screwed it into the door. Replaced the frame piece (also glued and screwed). Re-installed the door and it works great now. I used one screw and 2 rivets to attach the hinge. The screw goes through the hinge and frame and into the wood. The other two holes were too close to the edge of the wood to hold a screw so the rivets hold the hinge to the frame.

 

[BillM]

Don't know why but the pics got out of order but you can figure them out I'm sure.

 

[takesiteasy]

Nice job! Thanks for posting the pics.

 

[deethe]

ingenuity at it's finest!

(is your door really hinged right or is the photo flipped?)

 

[BillM]

Yes my door is hinged on the right, I have an Eagle Shell.

 

[deethe]

ah, ok- if i'd have read the door label i'd have realized it wasn't reversed...