Door Pin Bushing Removal

[cazman]

My door has been sagging again. Even after I thought that I fixed it. I have the Banks door pins, but the root problem is that the upper bushing in the body is worn. Has anyone removed this before? It seems to be "glassed in" snugly. Looking for advice before I try and persuade it out.

[Grumblebuns]

Has anyone tried to sleeve the worn bushing with possibly shim material?

[cazman]

I wonder how think the bushing wall is and if it will take a bore and sleeve?

[Gary t]

It should be possible to ream the bobbin  but getting the new larger hole centered on where it needs to be would be the tricky  bit. You would likely have to invent some sort of guide. If you can manage that the bushing should be easy. Red loctite as a retainer.

[jbcollier]

Is it worn or is it partially ripped out?

[EuropaTC]

I remember back in the 80s when I got my car Chris Foulds, a local specialist, gave me a list of things to look for and some potential fixes. In those days the hinge pins would seize in the door and wear away the aluminium body bush so he used to repair them with an insert. I think his were brass and threaded but memory fails after all this time.

A quick scan on SJS and.....

https://www.sjsportscars.com/parts-and-accessories/SJ046B0013.htm

Brian

[cazman]

Good suggestions and link.

I guess that I am not sure what I am looking at. Do you think this is the original Bobbin and there is a bushing pressed in to that? Or is the OE Bobbin without a bushing and the SJ bushing is a press in fix?

[4129R]

Good suggestions and link.

 the SJ bushing is a press in fix?

Agreed

The hard part is drilling an accurate hole for it to fit. But I think it is ally.

[BDA]

The bobbin is aluminum so the hard part will be to drill a perpendicular hole. I suspect that your bobbin is not irretrievably worn so the hole for the sleeve should need to be bigger than the hole you have. If not, that would be a new complication!

I would ask if they recommend using Loctite.

[Kendo]

That bushing also has a step in it at one end. If you don't machine a seat for that, it could get kind of tight to get a wrench in there to tighten the hinge (whichever hinge you have)

[cazman]

I agree.

[4129R]

That bushing also has a step in it at one end. If you don't machine a seat for that, it could get kind of tight to get a wrench in there to tighten the hinge (whichever hinge you have)

There is not much extra room with Banks brass hinge replacements.

[TurboFource]

When I rebuilt industrial high speed manufacturing equipment we used a reamer with a pilot (line reamer)
to line up holes that a pin or shaft went through.

[Kendo]

If the reamer holder had a tail that fit the lower bobbin, and the pilot at the top as TurboForce described, the reamer would be pretty well lined up to bore a suitable hole.

One thing to consider is that the two hinge bobbins are in fiberglass, not very rigid. It’s not like line boring cam bearing or the bottom end of an engine. There is probably a wide margin that would work just fine.

[Fotog]

I haven't spent much time understanding the details of your problem, but here's a link to a description of how someone went about sleeving the bushings in the body.  Maybe it would be of some help (?)

https://www.lotuscorps.org/wp/truing-up-the-body-fit-on-a-1973-lotus-europa-part-2/

-Vince