Door hinge repairs

Yep, think you'll need to cut the inner, just make a cut to join up with the upper hinge slot, then at 90 deg to that down then 90 deg to that on to join up with the hinge slot.

Then after a good scuffing up and degrease stick/wedge/ whatever a piece of plastic from INSIDE the skin to give you something to lay up on, an oval ice cream tub lid is ideal as you'll also have a return on it.
Have a scan through E200 resto thread and you'll see the plate I made for the inside and other details.
I think my spirit level is still marked out for the hinge distances, so I can help with that.
Make sure you reinforce with the plate shown and use a proper two pack automotive adhesive, don't be tempted with any boingy boingy single pack bobbar.

[BIG_MVS]

These look a right pain. Ryan you have definitely got mine to do over the winter if you can still do it for me?

Bob - I have a drivers door in North Yorks (less than an hour from Newcastle) if it helps?

Yeah, a pain, but when it's done.......it's done and better than ever.
And no rust to worry about.

Doesn't look too impossible.
Although I'm doing some welding on my Alfa at the moment and I admit it would be preferable to reach for the torch....

Top hinge anchor has cracked 3/4 of the way around, so reckon it's best to cut it all out and start again.



Bottom hinge has already cut itself out.

It'll be on hold for a week or two while I buy some fibreglass & adhesive, and I kinda have too much other stuff to do just now.

Looks like you've got it in hand, and to back up what I have said previously, the worse they are sometimes the easier it is ........nothing ventured, nothing gained.
Don't forget the spacing washers between the hinges and door.
With the hinges and spacers though you've got some adjustment allowance, I've considered opening up the square holes in the hinges to a round one and I reckon there's an easy 10mm of adjustment either way if needed.
Good Luck.

Well thanks to every one for their advice.
Last weekend I finally found the time and courage to go for gold and replace the top hinge.

I managed to use the ring spanner through the speaker hole technique by cutting away a little of the cowel inside. It was painfully slow progress but I found if I let it rest between turns it became easier to get the next 1/8th of a turn.

Once the 13mm bolts were out the next step was the worst ..... Prising up and out the old hinge from the bonding.

Then after opening up the holes a little with a cherry hot screw and a pair of long nose pliers!
It was time to reset the bonding and replacement hinge. Going back in was a lot faster than taking out. I found that the old holes in the metal plate on the other side of the central post centred the new hinge fine.

All in all a rewarding job, the photos below are in a rough sequence of events

Congratulations! Nice to see you get a result at last.
I'm not gonna waz on your onions and question what adhesive you used, I'm sure if the door is in good shape you'll be golden.
Bet you really enjoyed taking them bolts out! It's a killer on the forearms init ?

Taking the bolts out wasn't so bad really.
Getting them back in, however did involve some profanity................

Bet you really enjoyed taking them bolts out! It's a killer on the forearms init ?