Just curious if anyone has seen this damage at the hinges? Is it indicative of some larger problem? Can I just weld it up or does it need reinforcement?
Can you explore for rust inside the pillar?
My first thought was someone sat on the door which pulled on this area enough to crack.
My next thought was if your car had enough flex from rust while driving it could generate a fatigue crack over time.
With that being said, I think you could weld it up. You must keep the hinge plate loose though for door adjustment.
From the back side there is definitely a little rust but it does not look bad.
takes a lot of action to cause that fatigue
Does the door drop when it opens, do you have to lift it to close ?
Grind off the paint and get the full story.
That had to be from someone sitting on top of the door. That should weld up nicely.
Look at the bottom hinge mounting surface, is it perfectly flat, or is there a dimple at the very bottom, if so the door was forced downward.
Rusty seized hinge pins will cause this type of fatigue.
Unfortunately dealing with the same issue to a worse extent. The car had been sitting indoors for close to 20 years (much of it without doors installed), so I'm not sure what fatigue it experienced to cause this. Tried simply welding the crack before it was painted, but it reoccurred about a year later.
Purchased this to replace as much metal as possible and am toying with the idea of adding a reinforcing plate on top.
It seems odd that this would occur with the backing plate between the exposed steel and the loose plate
If you add a reinforcing plate to the new piece, add it from the rear if possible. I am surprised this failed again so quickly. How is the metal you welded?
It doesn’t need to be reinforced, just properly repaired. If it came back after a fix, it wasn’t the right fix and there’s probably more at play. You may have to remove the front fender and get to the overlapping metal pieces.
I was not talking about adding reinforcement. from the first endoscope image it looks like there is a thick steel "cup" between the visible steel and the threaded loose plate
One thought on this is that welds are brittle compared with surrounding sheet metal. It might be better to create a patch that moves the welds away from the chronic stress areas.
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