Lotusbits door beams and replacement pins

[tonypoll]

I'm sure it has been mentioned elsewhere, but be prepared to spend quite a few hours getting the door and window frame installed. It took me about 8 hours each side to get a good fit all round the door seal by adjusting the penny washers etc.

[John]

Hi Bill, glad you managed to get the beam fitted, frustrating that it wasn't easier.

Jeff, you asked about an adjustable reamer - I've not used one, but as long as you can set it accurately and take your time, a couple of thou at a time, it should work. You would need to check the reamer with a micrometer or digital vernier before cutting metal.

As regards reaming both bushes exactly parallel, I expect there's a taper on the reamer to give it a degree of self-centering but doing this by hand rather than in a machine is bound to be less precise. YouTube it first!

[Phantasm]

Tony, Yeah, I'm tracking that I've been going at this for 2 straight days - tomorrow as well. I had to rebuild the window lift channel today so didn't get much reinstall done - lots of prep though, rewrapping wires etc. I did put the door card back on and that is lining up nicely with the seals on the bottom, fingers crossed on the window frame.
I hope to get it all back together tomorrow barring no unforeseen issues. Namely my replacement window channel and new wheel on the actuator arm bodging things up. I used a set of drawer slides and modded the heck out of them. Right now the caulk attaching the replacement is setting up over night and should be firm enough to work with tomorrow morning. The old one was rusted out and the wheel was missing from the arm. It worked but made a go awful noise going up and down.

I tore down the other door this evening. For those following, I did use a copper bush (18mm water pipe joint extension/connector) and it installed very neatly and the pin fit like a champ without a need to ream it. I almost opted to forgo the last good Phospor Bronze bush I had left and put in a second copper one on that side as it was super easy to work with. however, I did do the PB Bush in the end and have it on the top of the hinge pin. The new beam for that side will go on tomorrow, letting the bracket's paint dry overnight. The rebuild on that side should be pretty straight ahead less the tweaking as I had it apart a few months back.

Here's my window channel rebuild.