Dealing with sagging car doors on your classic VW can be frustrating. Often, the culprit is worn-out hinge pins. While you can buy specialized tools, creating your own car door hinge pin tool vw style press is a cost-effective and satisfying DIY project. This guide will walk you through building a robust tool, similar to a Car Door Hinge Pin Tool Vw G Clamp in function, perfect for removing and replacing those stubborn hinge pins on your Volkswagen.
Gathering Materials for Your VW Hinge Pin Tool
Before you start building your car door hinge pin tool vw, you’ll need to gather some readily available materials. The beauty of this DIY approach is its affordability and simplicity. Head to your local Farm & Fleet or hardware store and pick up the following:
- Soft Bar Stock: A piece of 1/2″ thick, 2″ wide, and 3-foot long soft bar stock will form the main body of your press. This is the backbone of your car door hinge pin tool vw.
- Grade 5 Bolts: You’ll need 3/8″ and 1/2″ diameter Grade 5 bolts. These provide the strength needed for the press.
- Nuts: Collect 3/8″, 1/2″, and 5/8″ nuts to match your bolts and for creating the pressing mechanism.
- Soft 5/8″ Threaded Rod: A piece of 5/8″ soft threaded rod will act as the screw in your press, applying force to remove the hinge pins.
- Drill Rod (or Hardened Pin): For the press pins themselves, you’ll need a hard material. 17/64″ (.265″) drill rod is ideal, but you could potentially use the shoulder of a Grade 8, 1/4″ bolt or the smooth part of a drill bit as alternatives. The key is hardness for effective pin pressing in your car door hinge pin tool vw.
Constructing the Hinge Pin Press: Step-by-Step
Now, let’s assemble your car door hinge pin tool vw. The construction involves some basic welding and drilling. If you’re not comfortable welding, consider having a local shop weld the nuts for you, or explore bolt-together designs if welding is not an option.
- Prepare the Jaws: Cut and shape the soft bar stock to create the top and bottom jaws of your press. The design in the images provides a great template.
- Weld the Nuts: Weld a 5/8″ nut to the head of a 1/2″ bolt. This will be for the top jaw and needs to be threaded. For the bottom jaw’s 1/2″ bolt head, weld another 5/8″ nut, but remove the threads from this nut. This threadless nut will allow the 5/8″ threaded rod to spin freely.
- Create the Press Pin Hole: Drill a hole in the bottom jaw for the press pins. A 5/8″ deep by .265″ diameter hole is recommended. Drill a small through-hole as well; this is useful for removing a stuck press pin later.
- Assemble the Press: Use the 3/8″ bolts and nuts to create pivot points for the jaws, as shown in the images. The design uses double nuts on the pivot bolt to create some drag on the bottom jaw, which is helpful when positioning the car door hinge pin tool vw on the hinge.
- Prepare the Thrust Nut: The 5/8″ thrust nut on the threaded rod might need some modification. You might need to grind down part of its hex shape to allow it to spin freely past the weld on the bottom 1/2″ bolt head. File or grind any welds or bearing surfaces as needed for smooth operation.
Using Your DIY VW Hinge Pin Tool
With your car door hinge pin tool vw assembled, you’re ready to tackle those stubborn hinge pins.
- Position the Tool: Open the car door slightly to access the hinge. Pull the bottom jaw of your press down and out of the threadless nut. Place the tool on the door hinge, aligning the press pin with the hinge pin you want to remove.
- Engage the Threaded Rod: Place the threaded shaft back into the threadless nut on the bottom jaw.
- Apply Pressure: Begin tightening the 5/8″ threaded rod. This will push the press pin against the hinge pin.
- Press Out the Pin: As you tighten, the hinge pin will be pressed out. You may need to use different length press pins as the hinge pin moves. Start with a longer pin and switch to shorter ones as needed. If the hinge pin is particularly stubborn, penetrating oil can be helpful.
- Final Removal: Once the hinge pin is partially pressed out, flip the straight part of the top jaw over to the notched side. Place a 3/8″ nut (or stack of nuts if needed) over the hinge pin on the notched side and continue pressing until the pin is fully removed. If you need more space for nuts, you can cut the hinge pin shorter with a cut-off wheel.
Addressing Worn Hinges Beyond Pins
Sometimes, even after replacing the hinge pins with your car door hinge pin tool vw, you might find the hinges are still loose. This indicates wear in the hinge itself, specifically in the center moving portion.
The original creator of this tool encountered this and found a clever solution:
- Drill and Bolt: Run a 3/8″ drill bit through the entire hinge to clean up and slightly enlarge the holes.
- Custom Hinge Bolt: Use a Grade 5, 3/8″ bolt, cut to the appropriate length, as a new, oversized hinge pin. You can even add a homemade grease fitting/hole to this bolt for future lubrication.
This approach provides a robust fix for severely worn hinges, going beyond just replacing the pins.
Conclusion
Building your own car door hinge pin tool vw is a rewarding project for any VW enthusiast. This DIY tool is not only cost-effective but also proves to be a durable solution for removing even the most stubborn hinge pins. While commercially available tools exist, crafting your own provides a deeper understanding of the mechanics involved and the satisfaction of solving a common VW problem with your own ingenuity. Remember to always prioritize safety when working with tools and welding equipment. With this guide, you can effectively repair your sagging VW doors and enjoy smooth, properly aligned doors once again.
