Hinge plates

[Matt Neale]

The threads of the captive hinge plates for the drivers door have shredded.  Only one thread still works and as a result the door is sagging.  Has anyone got a solution that isn't too drastic.  I don't think I can get to them.  Can I use a tap and die set to re tread the plates?  Has anyone done this?

[JohnD]

Yes, I have.    Use a suitably sized drill to remove the old threads and retap for a larger bolt.
From memory the OE bolts are 5/16" and the holes on the hinge plates are big enough for 3/8"
This (and other) sites give the right sized drill for the next size of tap: http://www.prescottengineering.co.nz/Tap%20drill%20sizes.pdf
It gives the correct drill size for a 3/8" tap as 21/64", a size you may not have in your drill set, but 8mm is near as dammit. (40 thou as near)

John

[Pete Lewis]

the caged plates are very thin and doesnt take much to strip the threads , they dont like a lot of work, ive tapped oversize in 8mm metric and 3/8unf , if in real trouble you can hole saw  the a post and get a socket with a nut on the back of the plate, bit extreme ,  
if its the door captive you can with the cards off  fiddle a nut on the back , you may need to drill through the cage
and with bigger bolts you need to open up the hinge holes , it will restrict some adjustment movement.

Pete

[MarkB]

I've removed the captive plates from several cars that I broke. Long time ago but don't recall it being that hard. Think it involved levering part of the cage out of the way and sliding the plate out. Personally I would replace the plates and not drill and re-tap to a larger size especially more than one as you will reduce the amount of adjustment when refitting and lining up the door. In my experience these kinds of mods have a knock on effect.

Mark