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The Fox



Member Since: 24 Mar 2014
Location: Shrewsbury
Posts: 94
United Kingdom 2014 Defender 90 Puma 2.2 XS CSW Corris Grey
Hinge Fitting Advice
Got myself some shiny new Optimill rear door hinges to replace a set which were shot.

The bottom hinge (the awkward one, naturally) just doesn't want to line up. I can get one bolt through, but the holes in the body just don't line up with the holes on the hinge. The holes on the Optimill's line up perfectly with those on the old steel hinges.

I've tried loosening all the others and lifting/adjusting the door fit - but the holes just fundamentally don't line up. One of the holes is an oval from the factory - so I'm guessing they were just done poorly from day one.

Do I:
1. Make the other hole an oval and get the bolt through - drilling the body fills me with dread
2. Undo the lot and refit again - it's probably my bad alignment (how, if the holds just don't align...)
3. Just leave the bottom hinge with one bolt through the body - feels like the wrong idea
3. Other - answers on a postcard

Your sage advice gratefully recieved
Post #946617 22nd Mar 2022 3:49pm
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Shroppy



Member Since: 25 Feb 2016
Location: Shropshire
Posts: 866
United Kingdom 1986 Defender 130 V8 Petrol HCPU Aintree Green
Option 2, if the new hinges have the same bolt spacing as the originals then they will fit. They can however be quite tricky, especially if you're fitting them on your own.

I'm isolating at the moment but am not far from you so would be happy to give you a hand if needed? In the meantime, it may sound obvious but have you tried slackening off the the top hinge bolts? You may find the door is being pinched, preventing the second bottom hinge bolt from lining up.

EDIT

Something else to consider, are the threads ok? 1985 127 V8 Build Thread
Series 2 109"
Series 1 80"

Last edited by Shroppy on 22nd Mar 2022 4:58pm. Edited 1 time in total
Post #946624 22nd Mar 2022 4:44pm
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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 833
Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
Option 2. 2008 2.4 110 Utility Station Wagon XS.
Post #946626 22nd Mar 2022 4:45pm
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shropshiredefender



Member Since: 05 Jun 2017
Location: Shropshire
Posts: 834
England 2011 Defender 110 Puma 2.4 USW Santorini Black
Option 2 - loosen (don't remove) the bolts in all 3 hinges and you should be able to line up the bottom hinge. Worked for me! Just because you're offended doesn't mean you're right.
Post #946665 22nd Mar 2022 8:31pm
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MikeSel



Member Since: 21 Mar 2022
Location: UK
Posts: 10
England 
There’s a video on YouTube by The Doctors Garage of him fitting them. He has some tips in there, maybe worth a watch. Smile

Mine should arrive today, so interested to hear how you get on. Good luck.
Post #946709 23rd Mar 2022 8:10am
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The Fox



Member Since: 24 Mar 2014
Location: Shrewsbury
Posts: 94
United Kingdom 2014 Defender 90 Puma 2.2 XS CSW Corris Grey
Shroppy wrote:
Option 2, if the new hinges have the same bolt spacing as the originals then they will fit. They can however be quite tricky, especially if you're fitting them on your own.

I'm isolating at the moment but am not far from you so would be happy to give you a hand if needed? In the meantime, it may sound obvious but have you tried slackening off the the top hinge bolts? You may find the door is being pinched, preventing the second bottom hinge bolt from lining up.

EDIT

Something else to consider, are the threads ok?


This was my conclusion too - if the originals fit, why not these.

I'll have a go at Option 2 later today (at least we've got some nice weather for it) and report back.

Many thanks for the offer of help - I may well take you up on that!
Post #946714 23rd Mar 2022 8:51am
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DSC-off



Member Since: 16 Oct 2014
Location: North East
Posts: 1426
United Kingdom 2015 Defender 110 Puma 2.2 XS CSW Aintree Green
I had the same problem with the holes not lining up.
Something was clearly wrong, possibly why original top hinge broke
In the end I fitted the door on the top and bottom hinges, so it fitted the aperture and swung freely.
Then fitted the middle hinge, slotting the holes in the body to get the screws in.
Post #946722 23rd Mar 2022 10:24am
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steveww



Member Since: 05 Jan 2022
Location: Uppingham
Posts: 569
United Kingdom 2015 Defender 110 Puma 2.2 XS CSW Bronze Green
Remember Defender were hand built, tolerances are a bit vague.

When I did the same on mine, I had to open out a couple of the holes in the body by 1 - 2 mm. Then a dash of Duralac when you fit.
Post #946740 23rd Mar 2022 2:31pm
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