This original door hinge is from a 50 Ford Truck but not unlike the typical hinge of the 30s, 40s, and 50s. Often they rust thin in spots and its difficult to find replacements. We will show the correct procedures to make a hinge from scratch.
As seen from an aerial view the hinge has a slight angle and offset. This has to be duplicated exactly or the door will not fit appropriately.
We matched up a hole saw with the original hinge and then picked steel twice as thick to start our procedure.
Using the Clausing Drill press and a hole saw cutter we drilled at the precise angle in our vise to achieve our desired results.
A close up of the jig shows it was used to clamp the hinge like a sandwhich.
After an initial shave on the grinder the new hinge below is starting to come together.
Another view shows the need for a bit more massaging including trimming for length. This gives the general idea and approach to the procedures for hinge fabrication.
We ground the pin area round and inserted a new brass bushing. We then trimmed the length, drilled the mounting holes and bolted it up to the A-pillar. The new hinge is now ready to give years of service.
In place and looking good she is ready to mount the door and get on with the rest of the project!