TVR Vixen (late S1-on), 3000M,Taimar, 3000S, safety issue...

[Adrian@]

This a common error across the range for the DIY rebuilders in their 'quest' to replace anything for new whilst they are doing the job...There is a safety issue regarding the bolts for door hinges on the Vixen and M series cars, that the hinge bolts listed in the parts manual is for a ...Bolt hex head 5/16 UNF x 1 1/2 OR 2" (A. N). IN REALITY the A.N version of the bolt was not ever used (that I know of, I have never seen one in 40 years). BUT a dressed down headed 'special' bolt in place of the AN (layman terms, of the bolt is that it has a slim head) using a single anti-rattle washer. (Note.. that on the top hinge on the Vixen/3000M one special bolt is used, which bolts through to the engine bay, however the Taimar/3000S require two special bolts and that all the versions of the car bottom hinges have two). The reason for these special bolts is that the alloy part of the Ford Anglia hinge locks out on the heads of standard bolt head, (if addtional standard washers are fitted, more so) limiting the ability for the hinge to close freely.
Initially the fibreglass flexes (you might 'think' that the door seals are the limiting factor here), BUT, with door closed eventually this will break the hinge boxes off the car, AND OR fracture the outer shell (the box is attached to the inner side of the wing). A@

[Adrian@]

Jan,
As you have your cars in bits...
The hinge box back spacing/packing is all bespoke to each car (packed to get the outer lip hinge level with the upright post surface) with a square or two of pieces of loose FG the size of the back of the hinge (rather than the box) ...all done bespoke on production.
On your 3000M you are looking INSIDE the top hinge (one bolt within the hinge box (01015) and inside the lower hinge x 2 (01007) on the parts listing.
A@

Edited by Adrian@ on Tuesday 12th February 11:00

[Adrian@]

Thanks Mike, Here is the correct washer in that ...As I say above these were shimmed and spaced on production BUT the angle of attack from the door shell also is part of the issue this allows the hinge to rotate in further and limit out on the heads.

A@
We are also at a point where these are second and perhaps third DIY hinge rebuilds, in your picture is the OE FORD updated strengthener (welded into the hinge itself...that is missing on early Vixen's so there was not a problem in the OE TVR design) which brought the bolt heads forward.
A@

Edited by Adrian@ on Tuesday 12th February 12:29

[Adrian@]

Mike ...look at my last post, also relevant here is the added strengthener that would not of been in the OE design thought in '69, the alloy hinge is shimmed, with wear, the alloy locks out this too and jumps the edge (prior to locking out after time). It is worthy a little more thought than bluetack ...I have been correcting the issue for a long time and the cost incurred recently to rectify a near perfect paint finish, stood the guy in at 1800 UKP. A@