Door stay replacement

Tom '74 911 · 02-08-2007, 09:20 AM

Hi -
I'm replacing a door stay and can't get a socket in there to tighten the new bolts - the outside sheetmetal is in the way at the very top and very bottom of the opening. I've managed to get them finger tight, but am stuck after that. Is it a crime to dremmel (cut) the sheet metal out just enough to fit a socket in there? Is there another trick to getting these suckers installed?

Also - Is it fairly standard practice to grind down the (2) bumps on the new stay so the door swings a little easier?

Thanks,
Tom

mthomas58 · 02-08-2007, 09:44 AM

Funny you should ask. My relatively new door stay started making a clicking noise yesterday. I thought it was the cold weather but on closer inspection, the bolts had come loose. I don't remember it being as tight an area when I originally installed them, but without a socket available in the parking lot, I was able to tighten them easily with the 10mm wrench in the tool kit as you can angle them better than a socket.

I would not grind down the high spots. You will find the new stays very stiff at first but they will loosen up very quickly.

Good luck!

cak · 02-08-2007, 09:51 AM

You mean they're *not* supposed to make a click as they pass over the bumps? Mine make a very loud click at two positions. The stay was recently replaced (before I bought the car)...

mthomas58 · 02-08-2007, 10:51 AM

They will be very stiff at first and may even click at first until the break in but it will go away. IMPORTANT: Check to make sure they are not clicking because the door frame they are bolted into has failed. If it has failed, you may need a weld repair or the door stay reinforceemnt kit sold here (Part #PEL-PP911167)

Jetjockey · 02-08-2007, 11:01 AM

The loud click that you hear is probably the metal on your door flexing. This is a very common problem especially on drivers side doors (generally used more often than passenger doors) and should be fixed with a reinforcement kit before the damage is beyond repair.

lonewolf · lonewolf's Garage

if anyone needs
i just took off two good door stays from a pair of 72 doors

cak · 02-08-2007, 12:34 PM

Well, I checked at lunch. Both bolts were quite loose. That was easy to fix (they have a slot as well as hex head). Looks like I have the required 1-3/4" spacing, so I'll open up the door and install a reinforcement kit ... some day.

Thanks!

Tom '74 911 · 02-08-2007, 12:43 PM

Quote:

Originally posted by cak
That was easy to fix (they have a slot as well as hex head).

Thanks for all the conversation. Not much has been said as far as getting a socket head in to tighten the bolts - maybe I'm the only one w/that problem? Maybe a solution would be to dremel some slots in the bolt heads so I could use a screwdriver to tighten. . . hmmm.

Thanks,
Tom

cak · 02-08-2007, 12:50 PM

I'd go in there with a crowfoot wrench, myself.

NoLift911 · 02-08-2007, 01:41 PM

What you need is a 1/4 inch socket wrench, small head, 10mm socket and the key - small extension with a universal joint - makes this much easier and no need to cut out anything to get to the nuts.

Tom '74 911 · 02-08-2007, 01:47 PM

Quote:

Originally posted by nolift911
What you need is a 1/4 inch socket wrench, small head, 10mm socket and the key - small extension with a universal joint - makes this much easier and no need to cut out anything to get to the nuts.

That's exactly what I've got! And the 10mm socket won't fit between the bolt head and the sheet metal at the top & bottom. Take a look at the photo I attached in my first post - esp. the bottom bolt! There's no room.

I purused some older threads on this and saw one photo where someone used allen head bolts. I may try to locate some that will fit - then I'd have no problems at all. If that doesn't work, I may end up dremeling a slot for a flat head screwdriver. At least I've got options I guess!

Thanks,
Tom

Marco8 · 02-08-2007, 07:06 PM

I replaced both of my stays a month or so ago and don't recall having this problem. I used a 1/4" deep socket. No dremeling required.

Good luck

randywebb · 02-08-2007, 07:40 PM

try 6 pt. & 12 pt. - deep & shallow & a high quality brand that might be narrower than a cheaper one

Spin City · 02-08-2007, 07:47 PM

I replaced mine in October. My kit, from our host, came with allen bolts. Even if it had come with standard hex bolts, my '87 has plenty of clearance around them for a socket.

NoLift911 · 02-09-2007, 05:34 AM

Quote:

Originally posted by Tom '74 911
That's exactly what I've got! And the 10mm socket won't fit between the bolt head and the sheet metal at the top & bottom. Take a look at the photo I attached in my first post - esp. the bottom bolt! There's no room.

I purused some older threads on this and saw one photo where someone used allen head bolts. I may try to locate some that will fit - then I'd have no problems at all. If that doesn't work, I may end up dremeling a slot for a flat head screwdriver. At least I've got options I guess!

Thanks,
Tom

Has that door ever been damaged or repaired? That could lead to the misalignment issue - I do see by the pic (although it is tough to see if it is the angle of the pic) that there is not much space. General consensus is that the access does not require cutting - but in your case maybe it does. It looks like that entire inner piece has been shifted down and is out of whack?

Sorry couldn't be more help

-Jeff

Tom '74 911 · 02-09-2007, 06:21 AM

Quote:

Originally posted by nolift911
Has that door ever been damaged or repaired? That could lead to the misalignment issue - I do see by the pic (although it is tough to see if it is the angle of the pic) that there is not much space. General consensus is that the access does not require cutting - but in your case maybe it does. It looks like that entire inner piece has been shifted down and is out of whack?

Sorry couldn't be more help

-Jeff

Thanks Jeff -
I'm not certain if the door has ever been repaired - or even seriously damaged for that matter. I can't see anything obvious, but it certainly could be bent and I just don't know how to recognize what I'm looking at. The other door and stay look very similar - I've currently got both doors apart to put on RS panels, so it's easy to compare. Hopefully I can round up some allen head bolts today and be done w/it.

Thanks again,
Tom

schoward · 02-09-2007, 08:09 AM

My new door stay came with allen bolts as described above which made that a breeze since the slim allen wrench dives in there with no issue. Perhaps try to get the right bolts. I used the reinforcement kit sold by pelican with success (which comes with allen bolts as well).

My new stay was very stiff at first but broke in after about a week or two. The lube provided with the new stay seemed to work as designed.

fintstone · fintstone's Garage

SCHoward is correct. Note the photos of my '74 in the link below with regular bolts and allen bolts. It is tight. Get some similarly sized allen bolts.
Problem with door hinges "Clicking"