Door bolt sheared - anyone had this before? - MINI Cooper Forum

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post #1 of 5 (permalink) Old Mar 3rd, 2012, 06:28 PM Thread Starter
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Door bolt sheared - anyone had this before?

Hi,

Was oiling the car's door hinges when I notice that one of the bolts fixing the upper drivers door hinge had gone. It looked like the bolt had sheared.

No idea why...the only thing I can think of was the door got caught by a gust of wind a month or so ago.

There is still the remained of the bolt but it doesn't protrude any more and I'd need some sort of sleeve nut to fasten it to the door again.

I've attached a picture but has anyone seen the like...and have any other suggestions how to fix?

Tieak
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post #2 of 5 (permalink) Old Mar 4th, 2012, 09:13 AM
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The stud may have had a fatigue fracture in the metal since new or may have been overtightened in the past and just fallen off later. Not easy to fix as the studs are probably welded to the body. I would ask in a small local car body repair shop for advice..........they may be able to add another fixing screw or a blob of weld to beef things up. Be careful of any hidden wires behind or nearby whatever method is used if either drilling or welding.
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post #3 of 5 (permalink) Old Mar 4th, 2012, 09:46 AM
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Is this producing any movement when you waggle the door? My guess is that it isn't, in which case I would say thank goodness it was the bottom stud that sheared not the top one, as then movement would seem inevitable.

A proper fix would be a nightmare as it looks like the door would have to be removed and stripped. If it hasn't caused a problem so far, I would be trying to stabilise the situation rather than carry out a full repair - after all, 99% of cars never require their doors removed in their lifetime.

Plan A would be to fill the gap between the sheared stud and the hole in the hinge with epoxy putty - you can buy this in ready-to-use form from DIY places like in the photo below. You need to have some 'packing tools' ready to help you push the putty tightly into the gap without any voids - things like the wrong end of a (non-eraser!) pencil would be a good pushing stick. This won't do much to hold the hinge to the door, but it will prevent any movement of the hinge and so help the remaining stud survive as long as the car does. If the door ever needs to come off, this will make it more difficult, but then will lightning strike twice?

Plan B, if you have a friend with a machine shop, is to get a custom fastener turned from a piece of hex bar. It looks like there are still enough threads left on the stud to secure the hinge and enough gap around the stud to get a female-threaded boss into the hole in the hinge. But this would be a labour of love, so you would definitely need a friend to do it - if you could find someone to do it for money, they would probably charge most of the cost of a new door!
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post #4 of 5 (permalink) Old Mar 4th, 2012, 01:28 PM Thread Starter
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Thanks for replies, I also toyed with this idea

Thanks for both replies...it does look like a fairly uncommon fault.

At the moment the door still seems ok.

I was also thinking of one of these - the thread's still there and there does seem to be enough free space around the remains of the bolt to get one to fit in. With a washer to take the place of the one that's gone.

Now if I could work out what size to get, it may just come off (the plan, rather than the door).

Sleeve wheel Nuts with Flat Washers | eBay
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post #5 of 5 (permalink) Old Mar 4th, 2012, 01:54 PM
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Those sleeve nuts look like an ideal solution, if you can get them in a small enough thread size. You might need to make your own washer to fit the hinge, but that's not hard. And you might need to trim off the top of the nut with an angle grinder to stop it fouling the fixed side of the hinge, but that's not hard either.
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