Removing Front Doors MK1 2dr

[fastlaney]

Hey guys

cant find any old posts on here.

Just stripping down my mk1 for some panel and paint work. Having dramas getting the doors off.

Are there any particular methods or tricks to getting the pins out? Mine appear to be about 5/16 - 3/8 roll pins. cant seem to get any purchase on them whatsoever

thanks heaps

[Gary P.]

When I took the door off mine I used a tent peg of the correct diameter then bent the end of it to clear the top and bottom curvature of the door. I had to then keep rebending the peg as I hammered it further into the hinge. It worked really well.

[fastlaney]

thanks Gary

sounds easy enough, ill give it a go when I get a minute

Spent today measuring up for all the wood inserts (dash/doors). got a mate who is going to laser cut them out of some plate ally then anodise them. should looks sweet

cheers

[Gary P.]

FYI the peg I used was the one that comes with the OzTrail Deluxe shelters. Should be able to get one from your local camping store (BCF ?) Was the perfect diameter and not to hard to bend.

[PaulMK1]

I got a cheap (8mm?) punch from Bunnings. I also soaked the hinges in WD40 for a week or so prior.

On the last shell I got both doors off in less than an hour which I was pretty pround off!

[Gary P.]

Paul. How did you clear the curvature on the doors with a straight punch?

[PaulMK1]

Bottoms are easy - just knocked straight down and out!

The tops I punched up until they hit the curve of the door. I initially used a crowbar to try to bend the pin until they locked solid, I then used a air hacksaw to cut the hinge pin and then knocked out the remainder (also upwards).

[Gary P.]

Now it makes sense. I was trying to keep the pins intact. I'll probably just use a bolt when I eventually put the door back on.

[PaulMK1]

I have always treated the pins as scarificial - 8mm roll pins are cheap. But yes I have used 8mm long shank bolts on both of mine which make future removal very easy!

[Gary P.]

Unbelievably in the 32 nearly solid years of having an Escort this was the FIRST time I'd ever taken a door off one!!! Not planning on doing it again any time soon either!!

[fastlaney]

awesome thanks fellas

hopefully ill get into it tonight

Mark

[MK1_Oz]

I found that WD40 did nothing on its own. I used a paint stripping gun on the hinges combined with WD40. I heated the hinge as much as possible without letting it heat soak into the hinge itself (which would defeat the purpose). I tried a hinge pin removal tool which lasted precisely 3 hits!!!!!!! I then made my own tool out of some 2x1" off cuts with an 8mm steel dowel welded to the front. The extra length made the hammer blows easier. Once heated it only took a few HUGE blows to knock them out.

Horrible job.

Oh, don't dent your sills like I did!!!!