best way to remove rusty door hinges?? - Defender Source
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  #1  
Old July 5th, 2011, 10:36 AM
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rob grentz
1994 defender 90
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best way to remove rusty door hinges??

I kno this may seem like a silly question but hey arn't they all, I am replacing my doors on a '94 d-90 and the hinges are the ones that came with the truck they are rusty as heck and won't budge even after a good soaking..... I'm looking for any tips/tricks Thanks in advance
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  #2  
Old July 5th, 2011, 10:42 AM
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Kevin Buckley
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Try an impact screwdriver. If that fails drill the screws out.
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  #3  
Old July 5th, 2011, 10:44 AM
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What Kevin said. I had to drill through mine. It's easier if you can grab the bolt on the inside so it doesn't spin when you drill:

http://www.defendersource.com/forum/...7&postcount=83
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  #4  
Old July 5th, 2011, 01:30 PM
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Impact screwdriver. $30 or so at sears.
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  #5  
Old July 5th, 2011, 02:30 PM
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Matt
1993 D110
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I had decent success with a bolt/screw extractor set I got at sears. I busted several of the grabit style - they were fine for lighter duty, but could not stand up to the doors.
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  #6  
Old July 5th, 2011, 02:57 PM
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Jamie Austin
1992 110 Td5 CSW & 1989 MB G-Wagen
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IF the hinges are totally FUBARd, then a thin angle grinding blade and just slice through the whole hinge until you cut through the bolts.

Then replace with stainless hardware.
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  #7  
Old July 5th, 2011, 03:20 PM
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Jon Miller
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I recently replaced all of the original hinges on my '85 110. Some of the bolts were so rusted that they wouldn't budge, even with a good soak of penetrating lube. I had to drill a few of them out. I replaced the old hinges with TD5 hinges and used stainless hardware from Nakatanenga 4x4. I agree that if you can secure the nut on the other side, it makes removing them easier. Of course this next to impossible with the j-nuts. (have fun trying to retrieve those from your bulkhead if they fall in)
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  #8  
Old July 5th, 2011, 06:12 PM
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John B.
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The lower J-nuts are the problem.... Usually seized solid. Impact screwdrivers only go so far. I agree drill the head of the screws off is the easiest.
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  #9  
Old July 6th, 2011, 07:36 AM
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rob grentz
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Thanks guys I got the project done as I was only replaceing the doors and the hinges were good i was able to access the nuts from inside the door and tapped them out with a punch leaving the part of the hinge that is attached to the bulkhead in place.. Thanks for all the help
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