No spare tire on my dutch doors, what about fuel cans?

[Astrophysics]

Very nice work. I too would purchase that as a ready to install kit.
Where can I get Z71 4x4 decal?

Thanks,
AP

[Herbie]

Very nice work. I too would purchase that as a ready to install kit.
Where can I get Z71 4x4 decal?

Thanks,
AP

Thanks for the kind words. I was afraid this would generate interest. I have a CAD model for the over-hinges, so those would be easy to have made in bulk, but the base rack was a one off. Need to sketch up something that could be used intact without modification and see how much it would be to have the tubing bent...

The decal is from ebay. The seller I bought from doesn't seem to list that decal anymore, but there are plenty listed. It seems to be OEM quality, in that it's the kind you stick on with lots of Windex/etc. so you can slide it around to get it well-centered.

[Cobra]

that's a nice setup i'd be tempted to get one and those over hinges great i love them they should suit my needs (i guess wants would be more accurate lol)

[tgwms]

Thanks Herbie!

I started my own rack today using your walk through as a guide. I had some trouble getting the hinge pins out, so I wanted to post a few more details for anyone else attempting this.

Here is my press setup sliding off:


I used a 9/16" socket on top and a 3/16" (1/4" drive) on bottom. The lower pin popped out quick, but the top did not move. I bent my C-clamp trying to press out the top pin; I used so much force that the 3/16" socket swagged the tip of the pin into a hex shape and flowered it into the hinge hole:


So I drilled the top of the pin to relax the press fit and then punched the rim. This (I think) opened cracks for penetrating lube and maybe jolted the splines loose a little (pic after removal):


Then I cut the tip off my 3/16" punch and set it into the 3/16" socket to prevent more deformation while still allowing the pin to center into the socket under force:


I also switched to a 1/2" socket on top. This is a tight fit on the head of the pin, but I figured it was necessary to keep the stack aligned and balanced. It eventually popped loose. I switched back to a 9/16" afterwards. I ended up using some bolts and a deep socket with the C-clamp to press the pins all the way out... no hammering or other tools.

Things to try for a stuck pin:
> 1/2" socket on top for best press stack alignment
> Grease the threads and the anvil cup of the C-clamp
> Drill the pin head
> Deform the pin head with a punch to break splines loose and allow lube to penetrate
> Plug the 3/16" socket making the recess 'blind' to reduce deformation of the pin tip

I got the spine tacked together before calling it quits for the night:


Thanks again dude.

[photo_van]

missed this as it was happening, very nice job Mike!

My next project is duel swing outs, but I'm kinda over working on the van right now....

[Herbie]

Wow, great work tgwms.

So it seems that we haven't completely licked the hinge problem yet. One bent c-clamp per job, at least. :P

Can't wait to see how the rest of it comes out!

[SilverBullet1997]

Argh! I am fighting these rear door pins right now... I think what we really need is a tool dedicated to this job. I wish i had a welder so I could fab this up, but here is what I was thinking....

[Herbie]

Eastwood makes a door hinge tool that ALMOST fits, apparently. I've seen that a few people were able to use it after machining some additional clearance into it.

I'm still on the look out for something like a balljoint press that's a bit smaller. I can see it in my mind, but I don't remember the application. It's like a 4/5th scale balljoint tool with all the extra bracing, so it shouldn't flex as much as the C-clamps...

[SilverBullet1997]

I am thinking that modified tool that I sketched up would work really well, I think the only thing I would change would be to weld a bolt on the top of the screw head so you could use a socket to tighten it down... maybe even shorten the throw of the screw also, because really once you get the head to pop out getting the rest of it out shouldn't be a big deal

[SilverBullet1997]

Edited my drawing to better reflect what I was thinking.

[SilverBullet1997]

Rear Tire Carrier installed!


The carrier tips out to allow access to the hatch.

[T.Low]

That's all we get? More pics, more info!

[SilverBullet1997]

That's all we get? More pics, more info!

More info? ummm, steel, welds, paint, some mother F%#@$%ing rear door pins, and wallah!

[Spdcrazy]

One of my many projects this coming year. What's the end result on bulk made over hinge parts? Is someone making them?

[Herbie]

One of my many projects this coming year. What's the end result on bulk made over hinge parts? Is someone making them?

In the end, it was just simpler for me to just weld them up out of 1/4" cold-rolled bar stock. The machining steps needed to get the hinges made without putting in sharp-corners (stress risers) was going to make it "not worth it" for me. I've made two sets now and it really is just a matter of measuring & marking, drilling two holes, make a couple of cuts, then weld it all together.