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Demarte Toyota Soarer / Lexus SC400 Door Hinges - better than new.
June 2007 , by Peter Scott

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Daryl Demarte is a Soarer UZZ32 owner and Chopper Engineer. He is a licensed Helicopter repairer and flies all over Australia fixing the things. Last time he was in Adelaide he popped over and we were in my humble shed talking all things Soarer 'til late in the night. He's a top bloke and knows his stuff. He can refurbish a Soarer door hinge with four new bushes and grease gun fittings for $230 plus $70 refundable deposit. New hinges cost about $500. He is still chasing Soarer hinges of different colours - so that there will be a full set of changeover hinges in every Soarer colour. If you have some stuffed hinges going cheap that aren't bent, or need a changeover refurbished hinge then please contact him on  demarteemail.jpg (2080 bytes)

Here is what Daryl does to rebuild a hinge:

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The needle roller bearings are well past their use by date. As the original roller bearings were only made for Toyota ( I tried unsuccessfully to obtain the same ones at various bearing supplies all over the world) and these have a outside diameter of 19mm, the only needle rollers available with a 10mm ID have an OD of 15mm, with the rollers only a fraction of the size of the original. It would have required a sleeve to be made to take up the clearance from 15 to 19mm, so I have made the bushes out of Phosphor Bronze which is the best material you can get for the job, with the pins as required made out of 4140 steel. The actual bearing surface area of the needle rollers was only approx. 10mm in length, whereas the bronze bush has a total length of approx. 24mm so is a much bigger surface area.

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The bushes are reamed internally for an accurate fit and are an interference press fit into the hinge body. The bushes also have a flange which takes the thrust (weight) of the door.

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You will notice one of the pictures has a set of feeler gauges inserted, this is to measure the gap and the bushes are equally turned down so that there is minimum clearance, no slop, for a good finish.

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Finally there are grease nipples fitted at all 4 hinge bushes but they will only need a shot of grease once a year as they have been packed when being assembled. I turned a spiral groove in the bushes to allow the grease to move up around the pins, but until they wear in a little, the grease is hard to pump in. I will rectify this on the next lot of bushes and increase the size of the groove. The grease gun fitting required for these is a needle type end fitting

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This is the grease gun fitting needed to maintain the hinges. Tecalemit concave connector Part # HF 4034 at $15.79 +GST available at CBC Bearing Supplies in various areas in Australia.. This connector screws straight onto the end of the extension of your grease gun. Best if the extension is rigid not flexible.

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When fitting a hinge the wiring loom has to be disconnected. I thought it was easier to remove the plugs from inside the firewall rather than remove the loom from the door. I used a block of wood on a trolley jack to support the door. The hinge bolts allow adjustment to get the door to line up and close perfectly. Below is a pic of another project Daryl is working on - inscribed EMV buttons in English - not stickers-  but actual engraving the buttons so they light up at night.

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I have also attached a photo of an EMV surround which I have renovated by taking the buttons with the Japanese writing out, sanded the writing off, repainted the buttons, engraved the English words on them, given them a clearcoat matted down to remove the gloss and refitted them to the surround. Very permanent. Works very well at night with the back lighting.

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Daryl's car: UZZ32 #402