RCR40 MANUAL: DOOR HINGES
There are two types of hinges Original Style and RCR Style, each of which is described below.
** Original-Style Hinges **
First assemble your hinge plates with adjustments in the nominal positions, then mark and mount them on the door pillars as shown with bolt heads toward the door.
Mount the plates approx 5/8" from vertical ends of pillars.
Set doors in place. Carefully position the doors so the body lines and gaps are where you would like. Pay most of your attention to the bottom edge, A pillar and B pillar. The tops of the doors will appear low for low. This will be addressed later.
Cut two sections of the larger diameter tubing. The bottom tube will need to be short in order to be slipped in place. Slide these pieces into hinge plates. Shim up the lower sleeve until it contacts the door. While keeping the door closed and in optimal alignment, carefully mark where the tubes make contact.
Using a butterfly bit, drill the holes at your marked locations. Slide the larger diameter tube stock through the holes so there is approximately a half inch or so sticking out, mark the length, remove and cut to length.
Fiberglass these sleeves in the doors by precutting strips of fiberglass, inserting the sleeves into the doors, and rolling the fiberglass around the sleeves as shown in the example below. It is easiest to do this with a buddy, so one of you can work the fiberglass, and the other can spin the sleeve.
Finished external view.
Inside door view.
Once fiberglass has cured, install door, insert short outer sleeve sections into hinge plates, and insert the inner tube. Shim to position, and determine length to cut the small sections of outer sleeve which will be welded to the hinge plates.
Once you have reviewed all the body lines, and adjusted the shim stack to optimal position, tack weld sleeves in place. Do not fully weld the sleeves at this point. You want to have the ability to break them away if it is later determined more vertical adjustment is desired. Next, measure desired length for inner tubes.
Cut to length, drill through holes at the top and install a ring to assist with removal.
** RCR-style door hinges **
If you are utilizing the RCR-style hinges start the assembly much the same as the original, by mounting the hinge plate to the chassis and setting the door in place. Determine if shim plates are needed behind the hinge assembly by assessing if the hinge pivot holes align with the center of the door land.
Once you've determined the hinge is in the correct position, bolt it down securely. Then, mark the pivot hole position onto the door. Set the door plate in place and trace the adjustment holes. Drill all four holes and mount the plate as shown below.
Use nylon spacers and adjust as needed for optimal door swing and body gaps.
Determine desired approach to door checks. In this example, we used leather straps. Determine desired door swing, mark, drill and install. Keep in mind how the straps will stow when the door is closed. Confirm that they won't bind or look unsightly from the interior.
Be certain to use washers on the inside of the door.
Doors are now hung... time to fit the doors.