Door Hinges The first step I'm not looking forward to doing

[TahoeTim]

I am not looking forward to cutting out the 4 hinges and the backing plates. It looks like a lot of tedious work that is going to look like crap by the time I finish. I don't have the tools to do it nice.

Is there a pre-built alternative? Quick build hinges???

[Esser]

Hey Tim,

I felt the same as you. And then after I made them all, I scrapped one. A quick and easy way to make them is stick the amount you want cut off out of your vice and then lay your hacksaw side ways on the top so the vice acts as a guide. That will give you a straight cut and then it is just a bit of sanding to make them look nicer. You can you a sanding flapper wheel on a drill for a cheap fast way to dress them up.

[BobRS]

I had to remake one set of door hinges to get a better fit after installing door threshold U-channels so the paint does not chip when someone takes off the harness. If you have a bandsaw, the aluminum cuts easy after you've laid out the hinge and backing plate patterns. However... DO NOT cut through the steel pin with the bandsaw blade. Chuck it up in the vise and finish the cut with a hacksaw. Made the new set of hinges in <2 hrs. You can test this, but a 1/4" wood blade will cut aluminum if you go slow. Written up in Kitplanes some time back and I gave it a try.

BobRS
Alb, NM
SS7, 914 Turbo

[TahoeTim]

I cheated. I took it to a local fabricator that I use in my business. He chopped them up for free.

[Marvk7]

How are you all retaining the hinge pin?

[Esser]

You are supposed to stake them. I found pin material that was longer than the hinge. I bent it like an L so I could slide it I from the front and bend it slightly when it comes through the back so that I can remove the doors easily.

[TahoeTim]

That was my thought too. Where did you find the extra material?

[Dave S]

MarvK7,

Decided to drill & safety wire ours...If I need to take the door off...a bit of safety wire is pretty expendable/replaceable. A little planning to assure the holes are in the right place to prevent potential interference.

Dave S
KF 7 Trigear

[Esser]

My extra material came from when I had to reorder my hinge after screwing one up unfortunately

[jiott]

I believe I got extra hinge pin material from McFarlane's, but I think ACS also has it. Had to buy 3' of it.