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Old 12-16-2010, 08:51 PM   #1
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How to get brass sleeves into door hinges?

I had some sleeves lying around and decided to replace mine. They won't go into the lower door hinges I have. I measured the diameter of the brass sleeve and the pin hole in the hinge and the hole is .090 smaller than the sleeve. But the sleeves fit perfectly on the hinge pin itself. And without the sleeves, the door will hang pretty badly. Any ideas?

Thanks

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Old 12-16-2010, 09:46 PM   #2
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YJman:
I work with mchinery daily, I have not replace my bushings, but what you have mesured the bushings at tells me that they are a press fit bushing, witch means the you need to put them into your freezer over night, what this will do is srink the bushing smaller, grind a small tapper on one end so it will start easier,before you put them in the freezer, the next day check to see if the bushing has reduced in size, it will exspand quickly, keep them cooled for the next step, know you need to use a heat sorce, be it a gas accytlene or propane torch to heat up the hing, not read hot but up to about 250/300 deg. this will exspand the hing, be very fast inserting the bushing, the heat will exspand the bushing and srink the hing, practice the moves you will use to be as quick as possible, if it goes well the bushing should slip right in, but it might also drope through the hing, so put someting under the hing so that don't happen, when it cools test your hing pin you might find that the reaction of the heat and cold has made the pin hole small, then again maybe not, if it did you can ream it to size, or drill, you'll find that it's not brass but bronze, witch is harder than brass.

Hope this helps,

Roger
1995 YJ

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Old 12-17-2010, 01:54 PM   #3
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Thanks a lot. I'll have to try that!!
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Old 12-17-2010, 02:42 PM   #4
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Quote:
Originally Posted by ropanach View Post
YJman:
I work with mchinery daily, I have not replace my bushings, but what you have mesured the bushings at tells me that they are a press fit bushing, witch means the you need to put them into your freezer over night, what this will do is srink the bushing smaller, grind a small tapper on one end so it will start easier,before you put them in the freezer, the next day check to see if the bushing has reduced in size, it will exspand quickly, keep them cooled for the next step, know you need to use a heat sorce, be it a gas accytlene or propane torch to heat up the hing, not read hot but up to about 250/300 deg. this will exspand the hing, be very fast inserting the bushing, the heat will exspand the bushing and srink the hing, practice the moves you will use to be as quick as possible, if it goes well the bushing should slip right in, but it might also drope through the hing, so put someting under the hing so that don't happen, when it cools test your hing pin you might find that the reaction of the heat and cold has made the pin hole small, then again maybe not, if it did you can ream it to size, or drill, you'll find that it's not brass but bronze, witch is harder than brass.

Hope this helps,

Roger
1995 YJ
Wait won't heating the hinge melt the powder coat paint off of it?
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Old 12-17-2010, 04:10 PM   #5
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.090 is way to much of a difference for a press fit of a bushing that size check to make sure that the hinge is clean and free of any remains of the old bushing
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Old 12-17-2010, 04:53 PM   #6
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STOP YJman don't try anything.
I agree with Tyewilly
.090 is Ninety thousanths!, almost 3/32nds. There is no amount of heating and freezing that will make that much of an interference fit work, period. Even if there was a typo and you meant .009 that is still too much for a press fit with parts as small as we are talking about here. Parts this small would have a press fit of around .0002-.0004.
Double check to be sure the hinge is clear of debris like was said. If it is then looks like you need to either drill out the hinge or get the right size bushings.
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Old 12-17-2010, 10:09 PM   #7
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YJman :

I am so sorry, I seen the .090 as .009 I'm so glade you didn't try this with that large of a bushing, the most I have srinked on in this way was .o15, but that was on a (5") shaft, and I didn't think about paint
because that is all cleand of before I start the prosses.

Roger
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Old 12-18-2010, 09:14 AM   #8
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Lol okay I didn't try it yet but the sleeves are in the freezer. The hinges are brand new. I bought them a while ago and saved them. So they'res no debris in them.

I but each sleeve in a drill press and put a file up to it while the drill press spinned it. I made them a bit thinner. You think I should drill out the hinges a little bit?
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Old 12-18-2010, 11:31 AM   #9
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You might have too, after you have installed the bushing into the hing, you will need about .001-.002 thou. so the hing will work smootly, I've been told that you need .005, but I like to wear out the other .003, then you only need to ajust the hang of the door, and not change the hinges agian for a long time.


This is my 95YJ, taken this mornning at 9:00 A.M. on Dec. 18 2010
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Old 12-18-2010, 12:43 PM   #10
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A few thousants is still too much for a press fit on a part this small in diameter.
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Old 12-18-2010, 04:57 PM   #11
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Okay I guess I'll take a drill bit just large enough to shave the inside of the hinge. Let me go try that.
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Old 12-19-2010, 04:52 PM   #12
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I would file down the bushing like you did earlier. When talking about precision fitting parts such as the case when making a press fit it is important to have consistent size. Meaning a hole that is concentric and sides that are parallel. For these purposes a drill bit makes a sloppy hole, which is why press fit holes require at a minimum reamed sizing.
I know hand filing may not be the most precise but it can be controlled better than a drill bit.
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Old 12-19-2010, 05:40 PM   #13
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Has anyone tried the hard plastic bushings they sell on ebay???
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Old 12-19-2010, 08:04 PM   #14
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step drill the hinge, useing three diffrent size drill bits, first drill take out .050 thousands out,next drill bit take .030 out,last drill bit take out the remainder .010 out.use cutting oil and plenty of it on the last drill. You will get a tight uniformed hole,it's the next best thing to reaming.
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Old 12-20-2010, 02:04 PM   #15
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Oops... lol.

Okay, yesterday I did some more measuring and converting and I found I need a 7/16 inch drill bit to drill out the hinge just enough for the sleeve to fit.

Also yesterday, I tried a 27/32 drill bit. The sleeve is partially in but extremely tight, and now it won't come out. It's half way in. And some how it looks to be going in crooked. What should I do about this situation
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Old 12-20-2010, 02:17 PM   #16
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Take a round punch from the bottom side and tap it back out
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Old 12-20-2010, 04:28 PM   #17
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I tried that lol. But I filed down the edges so it would go in easier. So it's like trying to hit a pin with a pin...if that makes sense lol. But I'll try again.
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Old 12-20-2010, 04:37 PM   #18
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I'm a bit confused, what are you doing with a 27/32 drill bit which is.843 thousandths,when you said that you needed a 7/16 drill bit to do the job,7/16 is .437 thousndths.
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Old 12-20-2010, 05:36 PM   #19
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no sorry it was smaller than 27/32. We chose NOT to use 27/32s. Sorry I don't know why I said we used 27/32 :/ But it was something in 32s of an inch.
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Old 12-20-2010, 07:33 PM   #20
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The more this goes on I think it best you take this to someone who knows what they're doing. No offense YJman, I just see this project not turning out well considering the current course it is on.
Any Machinist, Mold maker, or Tool & Die maker can do this easily.
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Old 12-20-2010, 07:50 PM   #21
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yjman I am a machinest,do the step drill method I had mentioned,measure your bushing and step drill the hinge to that size,now if you find the bushing slides in to easily after doinng the drilling,take a prick punch and a ball penn hammer and make prick punchs on the outside of your bushing,where the punch marks are is it rises the surface of the material,do this on the entire outside of the bushing. add loctite and insert bushing.
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Old 12-21-2010, 01:41 AM   #22
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The biggest problem with him step drilling it is he most likely has a set of fractional drills. So he must work in .015 increments which is way too large of a jump. Another reason is a drill bit does not make a round enough hole considering the specs he needs to hold for a press fit on something as small as this bushing. Not to mention that he needs to hold some specs that are too tight to hold in an environment like a garage with home grade tools. Again no offense to YJman there are just limitations to what can be done with certain tools, lack of climate controls, etc.
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Old 12-21-2010, 03:26 PM   #23
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Both of you make good points. I'll try my best to step drill it as close to 7/16s as I can, then once I get close enough I'll just drill it out with the 7/16s. And no offense taken Ggg I'm only a kid still, just learning by the mistakes I make. My dad helps me as much as he can and all we can do is try He always tells me, we'll get it one way or another lol.
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Old 12-21-2010, 09:40 PM   #24
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Got them in!!

Step drilled out the hinge to 7/16s. Used a C clamp to press the bushing into the hinge. Drilled out the bushing and sanded the paint off of the pins so the pins would go into the sleeves. I'll cover them in white lithium grease and I should be good to go But the "powder coat" was damaged while doing all this so I have to paint the hinges...the powder coating on these hinges suck completely.

Thanks for all the help guys!!
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Old 05-07-2011, 11:59 AM   #25
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Door Hinge Bushing Replacement Instructions

Below is a link to replacement instructions for Wrangler door hinge bushings.

http://www.magnitude-engineering.com...structions.pdf
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Old 05-07-2011, 04:50 PM   #26
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I got them in a while ago hahaha but thank you very much for that link!! I'll definitely be saving that for when I replace them again. Very helpful, thank you.

The problem was just crappy hinges that china makes. When drilling out the lower hinge, we found that the inside was not even round..
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Old 03-03-2012, 01:57 PM   #27
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Door Hinge Bushing Removal and Installation Tool

Magnitude Engineering has developed a removal and installation tool for use with premium polymer replacement door hinge bushings:

Magnitude Engineering

The tool includes provisions for a fit check prior to installing the bushings to ensure the receiving bore is properly prepared.

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