Not counting the rear wing which could be considered type of a hinge, there are 3
types of outer body hinges in the car not counting for interior trim and
cubbies.
Door hinge pictures
 Those hinges had been modeled on
Lamborghini Countach
and Diablo / Murcialago OEM hinges which are very close tolerances to the originals. They are
custom made of machined cylinders and laser/water jet cut plates which in turn
are then welded
together.
The parts to have it manufactured and put together are much less expensive then
the original and are suiting our needs as the doors are bit pushed outwards
clearing front windshield when open and the fact that we wanted the
occupants doors swing upwards as the car is fairly wide where parking and
trying to get out of the car would be very difficult. For anyone wishing to make their own you
will need to download following CAD
files. The plates and cylinder are what makes up the actual hinge, you will need
to purchase Doorman pin # 38400
( specs ) to assemble it after the fact. To make the door
rigid and still and 3/8"anchor plate is
plate gets welded into chassis where the hinge gets bolted to.
just like originals elongated holes in the hinge allow for adjustment of the door and also aligning of
the body panels. The bolted part of hinge has outer smaller cylinders welded to
it with a gusset made while welding it together then ground to profile.
The larger part mounted to the door has a second plate welded to it to
provide additional strength plus allowing to have the cylinder welded
and aligned better. The cylinder is also drilled and tapped to that a
grease fitting can be fitted for lubrication once its all painted and
assembled. ..........more to come
Front trunk hinge
pictures
Front trunk hinges posed some deliberation of how it should be hinged.
One option was to have it hinged at the bumper line which would not
require double latch. It would also allow easy access to the filler caps
for washer fluid and brake booster inspection cap. Problem with it is
that it that its not very convenient to access the storage compartment.
_5.jpg) Trying to put the hinge at the cowl represents another set of
challenges. One major one is that the corners of the deck lid are very
long and wide so the deck lid would need to lift very high to clear it.
Second is that the caps most likely be covered by the deck lid so
viewing and refilling would be very hard. One advantage of it would be
that access to the trunk area would be very easy and eliminate the need
to hunch over the fenders to stow cargo in the compartment.
After making making test hinge located at the cowl it was noticed that
its possible to have it hinged up by the windshield however some other
configurations needed to be tested after making inner deck lid panel as
it was determined that the space for the hinge may not be sufficient
enough to be located in the very cramped clearance between the fender
and deck lid.
Having a small corner of the inner deck lid panel a clearance was
measured along the outer edge to see how much space there is for the
hinge. At one spot, clearance is just around 5/8' high, which is not
enough material for the arm and prevent it from bending. However if the
arm was to be thicker at that point it could compensate for the thinner
corner cutout thus straightening that spot of the hinge.
_5.jpg) A second test hinge was fabricated with longer arms as of the first
hinge. Though the hinge was very wobbly due to thin material used
it seemed to prove that the deck lid will clear the fenders and
surprisingly it moves forward far enough that it will clear the filler
caps at the cowl.
May 30, 2020
Realizing that to make the hinge very simple it will be required to
indent one or
_5.jpg) two
pivot points into the fender. The Indentation only needs to be big
enough for the plate and the 2 arms fit into it, though having extra
space will allow for easier washing and cleaning as it would be very
hard to do so if it where too small. Additionally may need extra space
for adjusting parallel alignment of left and right hinges.
..........more
Rear engine bay hinge
pictures
For the rear deck lid hinge we are using late 90's Volvo S70 rear trunk hinges
with air springs. The hinges provide enough tilt and lift to the bonnet lid
where allowing to access engine bay and clearing surrounding body panels
..........more
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