Door Hinge Pin Removal Tool

[Firewatcher]

Hello All,
Just to share a highly successful attempt to make a hinge in removal tool. Forgive my welding, but like my motor I am a bit rusty, and it was made as a workhorse, not a showpiece.
I post a few stage photos and give the dimensions of what I used, use your judgement on your design, but this one did work exceptionally well.
25mm x 10mm Blk Mild Steel flat bar about 130mm long. 18mm O/D x 10mm ID Mild steel tube about 30mm long. (I think this was a gearbox mounting bolt spacer in its former life)
3 off 9/16 UNF Nuts and 2 off 9/16 h/t hex hd bolts about 55mm long - (actually screws as they need to be threaded up to the head.)
The gap between them when welded as shown needs to be about 70mm.
I used two bolts, and reduced the diameter of the first one just enough so that I could get the initial 'Shift' without bending the tip. Reduced to 6.5mm about 7mm long. (No lathe, so just by eye on the bench grinder.) Used the mole grips just to hold while putting some pressure on and helped it along with some firm taps from the hammer. Worked like a charm.
Using the second bolt reduced to 6.5 over about 15mm will then allow the pins to clear the lower part fo the hinge and to disengage the top interference part. Then just the distortion and rust holding it, so not too diffivult to withdraw completely. Levered the lower one the last bit, but plenty of room to drift out the top one.
Seem to be having a bit of trouble getting all photos here, but hopefully you get the idea.
Pete

[Firewatcher]

Anyone interested in the photos I can send them by email.
Pete

[smithyiow4]

Hi pete yes plz as ive got too do my hinges too thanks john. Email to johnboy004uk@yahoo.com

[johnnydog]

Looks like a very useful tip to be included in a future edition of SIXappeal (Mike / Andrew?)

[iani]

I've been searching for a source of "9/16 h/t hex hd bolts about 55mm long" the longest I have found are 2", so 50mm, can anyone tell me a supplier of longer screws?

[johnnydog]

If you can't find a supplier of the required length of 'screws', could you not get a length of threaded rod, cut to length and weld a nut on the end? You would be welding nuts on the edge of the flat bar to make this tool anyway....?

[Firewatcher]

Thanks all for the interest in this post, but certainly this tool made the job much easier without resorting to heat or damage to the adjacent door post & wing edge. The original brass washers were also saved and in remarkably good shape so re used. I know there is a way of adding multiple pictures to a post, but it evaded me (and still does) when I did the original post. so just send a private message & I will send all pictures in a zip folder.
I am no longer a member of the journal now, but yes might check if I can still add something as a non subscriber.
The bolts were from my prized collection of imperial nuts & bolts saved over the years for just such jobs, but I only had three, so can't offer to send on. Not sure of the metric fine equivalent, but I am prety sure the standard thread wouldn't take the strain, these pins are tight.
One final comment is that the centre leaf was very worn, so using the replacement pins from Chris Witor of the original size still allows more movement than I expected. Bushing those (see older post on this) seems to be the ultimate solution, and I may well try and find someone to do this when I can find time to get back to it.
Pete
PS The pins are only an interference in the top lug of the hinge, the lower and centre are both just a good fit. The main resistence seems to be from the distortion of the pin as it wears, together with any rust that creeps into the top and bottom lugs.

[wild bill]

Hi,
are the screws/bolts you are seeking 9/16" diameter, or 9/16" head-spanner size,I.E,3/8" diameter.I may be able to help you out with the latter.

[Firewatcher]

Hi Wild Bill,
Yes, 9/16 A/F - My mistake in specifying them, so they are actually 3/8 UNF. Force of habit just thinking of the spanner size. Iani is the one looking for some and I have sent him the photo. I will let him know you might be able to help, and thanks for raising the correction.
Pete

[iani]

Hi,
are the screws/bolts you are seeking 9/16" diameter, or 9/16" head-spanner size,I.E,3/8" diameter.I may be able to help you out with the latter.

Hi Bill,

It doesn't seem easy to find these screws fully threaded to 2.5", can you please tell me your source?

Ian