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My misfortune

3K views 32 replies 19 participants last post by  rednroll 
#1 ·
I'm all for admitting mistakes and learning. That being said maybe I can save someone from the same misfortune.

Today I decided to go ahead and get my Star Fabricating hinges installed. Armed with my tools and the Teraflex install video I was ready to begin. That was were the success ended today. DISCLAIMER: The Teraflex video must be older, they instruct using a 1.75in Bi-metal home saw. Unfortunately I didn't actually read the included instructions from Star. It's actually a 2in hole saw. You can guess we're this is going. I marked everything with the utmost attention to detail and made the first cut (with the 1.75in hole saw). Afterward I tried putting the hinge in to ensure everything was lining up to make the horrifying realization that my hole was .25in too small.

This operation quickly turned from modification to a salvage. I I attempted to cut a wood template that could be secured to the door and used as a guide to get the hole widened.

That didn't work. As soon as the saw bit into the metal it snapped the wood and boogered up the door jam.


I'm pretty disappointed, but it could always be worse. This is a rarely seen area and once I get it "un-boogered" it will be mostly covered.

My next plan is to grab a dremal grinding bit and try to enlarge the hole enough to fit the hinge- fingers crossed. If that fails I'm thinking getting a piece of metal cut to fit as a template (like the wood). That should be stout enough to guide the hole saw.

I'll post some pics when I figure out how to fix it. Anyone with ideas feel free to chime.


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#2 ·
Make you wooding guide again then use the dremal to widen the hole.
 
#3 ·
Try to place the wood inside the existing hole and use it to center the hole saw, then use delicate pressure when making initial contact with the metal. I think that you can salvage this if you can careful. Good luck!


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#4 ·
I agree with TerryC6!

Trying to use a hole saw without having the pilot hole to spin on is nearly impossible. The saw just tends to walk all over the place and booger the surface up like you experienced. Your best bet would be to go with another wood template and grind the hole bigger with a Dremel tool like mentioned above.

Let me know how it works out!

-Jake
 
#7 ·
I'll post some pics when I figure out how to fix it. Anyone with ideas feel free to chime.
Man, that sucks. I don't know how many times I have done something similar lol.

Try going to the lumber yard and get a piece of 1x6 composite (deck board) and use it instead of the wood. Might put a little oil on the metal you're cutting to help it get started.
 
#8 · (Edited)
The wood idea as a guide for the holes saw will work fine.... just not with wood. Find yourself a piece of 1/4" polycarbonate (lexan) or a 1/4" piece of aluminum and go at it again. Ease into it and it will go right through. We scallop stainless 304 sheet metal panels all the time doing exactly that method.

Btw... Polycarbonate, not Acrylic!
 
#9 ·
Tough luck and a reminder that real men don't need instructions..... now you get to demonstrate real man recovery! It's like building anything - anyone can build something, but a pro learns how to recover from mistakes.

I like what you did with the dowels to center the wood profile.... that's a professional approach. If it was me, I'd make another wood profile and use the dremel to grind the door hole edges until the hinge piece fits. It'll be slow going, but it'll work. Once it fits, I'd paint any bare areas with an OE touch-up kit, install the hinge with sealant all around and call it good.

Worse things have happened and like you said, once it's all done, you won't see it. Just be careful you don't grind too much in the east/west - side/side directions because there's not too much coverage of the hole by the hinge plate.
 
#11 ·
I like the dremel approach. I'm a little gun shy on that hole saw and I don't know where to find polycarbonate. The way the hinge is designed I don't think it will need much grinding E/W. it's more vertical than horizontal. I believe with the template guiding me so it should be fine, but I definitely noticed there isn't much margin E/W. I already have touch up paint and silicone ready to go. I don't think it will be very noticeable at all.

Hopefully I'll have it fixed in the morning. I bought two packages of grinding stones at H. Freight this evening. I'll post photos!

Thanks for the pep talk!


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#12 ·
I have these stops coming Monday. Although I already read about the change from 1.75" to 2", I'll definitely remember now.

For anyone wanting a set look up Mopar item number 82214790 for FRONT pair. The rear set is a different number. Cheapest price was through random dealerships around the country, since this is a Mopar part they have them in their catalog. I actually don't think Star Fab makes these anymore although I believe they originated the design.
 
#14 ·
OP I know the feeling, I've done that kind of thing before. You're all ready, got the tools lined up, read the instructions, watched videos, then something so simple just goes south.

Happened to me yesterday, stripped a lug nut when swapping my stock tires for 35s. Had to beat the hell out of the lug and reverse it out with those sockets with teeth inside. Simple shit turning into a bigger job than it should have been, happens to the best of us.

I'm sure you'll get it figured out though, best of luck to you!
 
#17 ·
OP I know the feeling, I've done that kind of thing before. You're all ready, got the tools lined up, read the instructions, watched videos, then something so simple just goes south.
Sounds like every project I've ever worked on. I always read these posts which say, "it's less than a 2 hour job." I kind of just laugh to myself and say, I better quadruple that time estimate because nothing ever seems to go as planed when I'm doing it.

For example, I installed my lift by myself. Most say, it's typically a 6-8 hour job. I spent 4 full days. My time estimate was right on target. :D
 
#15 ·
The grinding stone was a success. Albeit a lot of work, but it's finished. I didn't really grind too much on the E/W sides, but by the nature of how it fits in, there is a very, very small gap in the left edge with the hinge installed. It should be easily sealed when I silicone it. I have a coat of paint on and I'll probably do several more to build it up. I'm happy with the recovery. I'll post photos of the hinge installed later.




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#23 ·
When us DIY guys take things on, we have to remember that it's not the mistake that counts, it's the recovery! Nicely done sir!
 
#24 ·
Looks like you were able to recover it really really well. End product will look flawless!

For anyone questioning whether or not to try this yourself, this is my story...I was horrified at the thought of drilling into my Jeep; I am also not very mechanically inclined. So I watched as many videos as I could, read as much as I could and even called the company for tips (they pointed out the 2" change). I went OCD with the first door and it took 45 minutes. The three remaining doors took 45 minutes in total.

This is a game changing mod. Those with it understand; those without it never will.
 
#27 ·
Holy sh!z. Project has been quite the pain!

Lesson 2: Pre-drill the hole for the hole saw. The hole saw bit is so short that as it clears through the material there isn't enough time to relax pressure so the hole saw it self makes contact and jerks bending the bit and chewing up the hole a bit.

All that being said, this is one of those seemingly simple mods that once it's on you realize how completely amazing it is.




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