Door hinge / jamb repair

[Sveedy]

I've been dealing with the door ( drivers, LH ) making the dreaded popping sound whenever it is opened or closed, for a few months, but yesterday it really broke free. I had this happen a couple of years ago with the other front door, and fixed it in this same manner. I think the repair will last longer than the original design, do to adding a small piece of steel in the last step of the repair.
I welded everything, but I believe you could do it with cold weld ( JB Weld etc ), and still have success.

First, peen / flatten the broken body metal. Then wire wheel the paint off from that area, and all around the hinge base. You might need to pry the hinge base back out a little to close the gap between the body metal and the base. But I didn't need to on either door.
Weld everything back together as best you can, and grind flat.
Now the take a small piece of 1/16" sheet metal ( 1" x 2 1/4" ) and slip that behind the welded nut on the hinge base. Tack weld ( or JB Weld ) that piece to the body metal. It doesn't need much; just enough so it doesn't slip out.
It's this little piece of metal that prevents any future movement, as the force is pushing it tighter to the body.
Yeah, I threw some paint on it, but you won't see it when everything is back together.

And it doesn't cost diddly.

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[wizechatmgr]

Looks like you hit it with a mig, which should provide plenty of penetration. I wouldn't go the JB Weld route just because we know that whole area has a propensity to flex. That said, it would be better than nothing for someone in a jam and without welding equipment =)

[erikv11]

Looks clean and sturdy, very nicely done!

For those who haven't invested the money/time into welding equipment/skills or with only hand tools for whatever reason:

viewtopic.php?p=585922 and some links therein, etc.

The hand tool method goes back to the good old days of the Ozbrick fora in the early 2000s. I've patched up three P80s so far this way (2010, 2016, 2021). I no longer have the 850 I did the fix on in 2010 but the other two are holding up.