"How to" Install VDi Lambo Door Hinges

Deepbluegxp · 09-21-2008, 06:57 PM

Hinges will be here Wednesday. So I used today to do some of the prep work using the instructions from Vertical Doors Group Buy at DDMWorks. The instructions are for a 2006 Solstice so the information on the ECM and components to be moved are different.

Today I only removed the quarter panels and frames, made the cuts to them and reinstalled everything. It's my DD.

All photos are here. deepbluegxp/2008/2008-09-21 Lambo Door Hinges - Page 1 - Photobucket - Video and Image Hosting

Start by removing the quarter panels. I placed yellow marks for the screw locations.

Since I have Norms Side Skirts, I have them pulled down. BTW, they are held on by industrial velcro along the sides

I also had to remove the mud flaps (trimmed to fit the side skirts)

Quart panel removed.

Drivers side quarter panel removed.

Pull off the frame bolts 2 x 10mm.

Mark the location of the edges of the frame to the brace with tape for installation allignment. Nut is removed from beneath with a 10mm deep well socket.

Frame removed

Tape aplied to show where it needs to be cut. I used a jig saw. All edges were de-burred and painted to protect them. I used a Enamel Gloss Black for the frame and touch-up paint for the fender.

Deepbluegxp · 09-21-2008, 06:57 PM

Taped off section to remove on the quarter panel

Top cut out section completed.

Wiring harness protector has two push plugs into frame. Remove the cover

Cover it with electrical tape. This will be zip tied to the hinge at a later time.

More to come after I get the hinges. I did the above to both sides and reassembled the car.

Deepbluegxp · 09-21-2008, 06:57 PM

Drivers side only. All are 10mm bolts. Remove the frame support bracket by removing these two bolts.

Remove the windshield reservoir (3 bolts) disconnect the pump connector and supply hose.

Once the reservoir is removed. Remove the ECM bracket bolt (above picture) and the lower right bolt.

The ECM bracket has a plastic clip holding the windshield supply line, pop that off and then cut/trim the bracket along the right bent area removing the tab.

Then use while pressing the ECM back against the angle support, use a punch in the existing hole and mark a location for drilling.

Drill and Tap with a 6mm tap and appropriate bit. I drilled through and tapped only the first surface. Then I added 4 washers to the bolt to prevent it from bottoming out.

Take the reservoir and use a using a marker to indicate where to cut and to elongate a hole.

Notice the elongation mark is on an angle.

Be careful not to cut into the tank.

Deepbluegxp · 09-21-2008, 06:58 PM

Press the ECM bracket back to the angle brace and install the bolt in the newly tapped hole. Then install the lower right ECM bracket bolt in the original position. Install the reservoir elongated hole bolt first snug but not tightened. Then install the reservoir upper right bolt back into the ECM bracket. As you tighten, press the reservoir towards the ECM. Then tighten the lower bolt. The bottom right bolt is not used. Reconnect the pump and supply line.

Prepare for stock hinge removal.
Open doors, remove the door detent bolt and push it into the door (the flap will not go inside) This is difficult and bracing the flap against the car frame, then closing the door will push it in. (If you do not do this, you will not be able to open the door after replacing the hinge) Reopen the door and apply tape on windshield frame and squat down until your eyes are level with the flat surface of the door. Use a permanent marker and draw a line on the tape level with the top of the door (this is important, the door will sag a little when you pull the old hinge off and serves as a reference to position the door).

Close the door.

Use paint sticks, 3" pieces, and wrap tape around them until they fit in the door edges. Insert one even with the door handle and on the bottom of the door. hold it in place with a piece of tape. Use several pieces of tape from the door to the windshield.

Apply a piece of tape to the front edge of the door by the hinge bolts to protect it. Remove the old hinges #10mm and #13mm bolts.

Install the new hinges, hand snug the 4 long bolts with washers against the car frame. Install the 4 short bolts with washers into the door. have a friend hold the door up to verify the top of the flat surface of the door is level with the line you previously drew on the tape. Tighten down the door bolts then tighten the 4 bolts to the frame. Adjust the bolt with the jamb nut to stop the door from sagging. This adjustment will allign the door striker to the latch. Then remove the tape and have a friend support the door to install the piston. Readjust the door as required, never loosing more than 3 of the 4 bolts on the door or frame.

Apply tape on the inside of the hood for marking off the hole to be cut.

A picture of the template is attached so you can make one. Cut out the green portion of a 8 1/2 x 11 sheet and write left and right sides on it. It is best to print on a regular sheet, cut out, transfer to a thicker material. The right lower corner of the picture goes to the corner of the hood.

Use a cutting wheel to carefully remove the metal

While the tape is still on, spray the inside of the hole black or another color close to your body color to make the hole less visible. Remove the tape and debur the hole and touch up with paint.

Do this to both sides of the hood.

Close the hood and check for alignment to the door, if everything looks good, then reinstall the quarter panel frame and quart panels. Then there is one more set screw to adjust to prevent the door from opening too far and hitting the fenders.