Right Rear Door. Let's now finish the door hinge saga with the right rear door

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1 Right Rear Door Let's now finish the door hinge saga with the right rear door You may have been already guessed my steps, so there is not much to describe in detail. Old upper one file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (1 of 15)26/05/ :45:06

Old upper one file:///c /Documents and Settings/Administrator/My

2 Old lower one Fasten together the door frame to B pillar file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (2 of 15)26/05/ :45:06

3 and undo the hinge bolts Here you see the hinge taken out using a slim knife file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (3 of 15)26/05/ :45:06

4 Got it out clean everything up file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (4 of 15)26/05/ :45:06

5 Same for the lower one these are the spacers and their adhesive aluminum foil wrapping them around - this is adhesive foil just for sticking hinge to body part while you are about to torque down the bolts. file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (5 of 15)26/05/ :45:06

adhesive foil just for sticking hinge to body part while you are about to torque down the

6 Apply seam sealer and torque down the bolts. file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (6 of 15)26/05/ :45:06

7 Apply seam sealer to the gap between hinge and body panel in both hinges. file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (7 of 15)26/05/ :45:06

8 End result before painting the sealed area Mask everything out file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (8 of 15)26/05/ :45:06

9 Detailed view of the masked area around upper and lower hinge file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (9 of 15)26/05/ :45:06

10 fresh paint has just been applied in the upper... file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (10 of 15)26/05/ :45:06

11 ... and lower hinge end everything's appears nice and neat! file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (11 of 15)26/05/ :45:06

12 also very nice even at a closer look! file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (12 of 15)26/05/ :45:06

13 This is rubber protection for the lower part of the door. I have replaced all four weather strips but only here you can see documented the process since the process is standard. remove the plastic tabs in order to get the rubber strip out file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (13 of 15)26/05/ :45:06

14 and be sure to clean the bottom using a toothbrush and plenty of soap. Install the new weather strip by pushing the tabs inside the small holes as seen at the previous photo. file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (14 of 15)26/05/ :45:06

15 I also found it practical to clean the inside of the door. It may sound weird to you pouring water inside the door but there is no need to worry. The door is designed to expel water from a couple of oval openings at the bottom, as you can see in detail in the photos above. That's why older cars would rust at the door bottoms as there was no drain provision. Door hinge project is over now... I'm totally satisfied with the end result with no rattles or knocking sounds! I owed this to everyone claiming that Italian cars rattle from every side. (c) 2006 Thanassis Gritsopoulos 1991 Alfa IE Athens - Greece file:///c /Documents and Settings/Administrator/My Documents/Photos/Alfa/Επισκευ ς/μεντεσ δες/π σω εξι /Bob/right_rear2.html (15 of 15)26/05/ :45:06

That's why older cars would rust at the door bottoms as there was no drain provision. Door hinge project is over now.

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