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How The Hell Do You Take The Doors Off A Zook?

Tech Talk for Suzuki owners.

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How The Hell Do You Take The Doors Off A Zook?

Post by JacZook »

How The Hell Do You Take The Doors Off A Zook?

I Have tryed everything, Air Rachets, Socket with Phill Head on it.

The hinges just wont come off

Please help

Cheers
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Post by cazook »

Try a impact driver
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Post by Highway-Star »

Never done it myself, but have you tried an impact driver?

I assume you meen the screws on the hinges. One end of the hinge is welded to the body I think, so only one way to remove them as such.
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Post by suzuki boy »

There a prick! :bad-words:

Broke 1 impact driver and got them all out except for one i had to grind off! :twisted:
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Post by MART »

centre punch near inner edge , punch it once straight then angle it and turn the screw head by hiiting punch , this has worked every single time on many zuk's , Cheers paul.
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Post by smileysmoke »

once removed i would suggest replacing the screws with bolts or allen key head bolts.. something other than a screw head!
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Post by short stuff »

use a chisle and unscrew it with the chisle works all the time
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Post by sanger »

Impact driver and a BFG.
Chisel
or small flame torch head head and unscrew
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Post by Bazooka »

Used an impact driver bit in an 8mm socket and ratchet. Gives a lot more leverage and has never missed. Have always been able to get any door screws out this way.
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doors off zook

Post by want to be a wylie »

use ur impact driver but tighten the screws to break the factory locktight first then undo them.
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Post by skez »

i have done this heaps and with a impact driver worked for some until it broke or a cold chisel works to.. if all else fails weld a nut to it then undo it.
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Post by CRUSHU »

Get an air hacksaw and cut the top arm off each hinge, so that when you open the door, they will just lift off, if the straps are undone. That is what I did to mine.
Took 2 seconds to remove doors when I wanted to. And 2 seconds to get them back on.
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Post by N*A*M »

needs heat and/or impact to break the factory thread glue

no matter what, you will destroy the stock screws so go sick
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door screws

Post by want33s »

Forget about an impact driver.. You will only smash bits and dent panels.
Get a hammer and a good cold chisel. Works for me. NO damage to paint on doors, body or hinges, however screws will need replacing. Use Nevaseeze on new screws. Stainless buttonhead capscrews are the go. :D Image
Last edited by want33s on Tue Jun 12, 2007 11:52 pm, edited 1 time in total.
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Post by offroader-rama »

impact driver
every suzuki owner needs one, there screews are so bloody tight, they work everytime.






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Post by Gwagensteve »

I have also found the impact driver to push the panel in rather then undo the screw - especially on the top screw of the top hinge.

I have used a cold chisel for ages, neve had one beat me.

The quickest way is an air chisel with a screwdriver attachment. Bluepoint (Snap-on) do these and while the air chisel is shocking the screw you just turn the lever and viola! - any screw is undone!

PS I have had a car at home with cut hinges and they make me nervous. They are quick (but so is undoing 8 screws) but aren't as secure.

Steve.
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Post by Longbaser »

Yeh, the ultimate challenge in rebuilding a Zook!

I went through this after getting a good pair of doors to replace my rusted out ones a few months ago. After shattering several impact driver bits, and having seen the damage a cold chisel can do if it slips at the critical moment, I dug out my old set of Eazi-Outs.

Drilled a small hole in dead centre of the Philips head slots (can't remember now what size drill bit I used, or what size Eazi-Out!) and they all came undone with relative ease. If you are careful, the screws can be re-used, though I had to replace a few that I had savaged with the impact driver.

Incidentally, I do like Want33's idea of the stainless buttonhead capscrews to replace the original crappy screws! :armsup:

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Post by Guy »

Gwagensteve wrote:
I have had a car at home with cut hinges and they make me nervous.
Steve.
Why so Steve, the doors are about as tough as a coke can anyway.
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Post by Gwagensteve »

Hmmm, after buying hundreds of stainless caps for flare mounting etc, I am not really a fan. Button heads are shallower than normal cap heads and I have had heaps of trouble with them galling and the hex burring.

They might be ok for door mounting because they don't require much torque and are unlikely to get much imapct damage, but once the stock screws have had their locktite broken they seem the best option to me.

Steve.
[quote="greg"] some say he is a man without happy dreams, or that he sees silver linings on clouds and wonders why they are not platinum... all we know, is he's called the stevie.[/quote]
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Post by =SKB= »

Image
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Post by Gwagensteve »

Much nicer to work with than button heads but less bling.

Steve.
[quote="greg"] some say he is a man without happy dreams, or that he sees silver linings on clouds and wonders why they are not platinum... all we know, is he's called the stevie.[/quote]
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Re: door screws

Post by suzuki boy »

want33s wrote:Forget about an impact driver.. You will only smash bits and dent panels.
Get a hammer and a good cold chisel. Works for me. NO damage to paint on doors, body or hinges, however screws will need replacing. Use Nevaseeze on new screws. Stainless buttonhead capscrews are the go. :D Image
Those doors look familia!

They came up very well!
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Post by fool_injected »

After you do get the mongrals out it doesnt what bolts you use if you dont put a little anti-seave grease on it
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Re: door screws

Post by want33s »

suzuki boy wrote:
Those doors look familia!

They came up very well!
Yep, I like them. Thanks Nath. Bit cold to use them at the moment, will have to wait another few months. :cry:
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Post by BlueRidgeRunner »

If all else fails then knock the paint off the head of the screw and weld a nut to the top of the screw. Then use a wrench that fits the nut. I had to do that to get the screws off a couple of my hinges.

Here is a permanent fix:

http://www.izook.com/tech/samurai/doors ... ngecut.htm
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Post by Gwagensteve »

love_mud wrote:
Gwagensteve wrote:
I have had a car at home with cut hinges and they make me nervous.
Steve.
Why so Steve, the doors are about as tough as a coke can anyway.
Dunno - just makes me nervous. halves the strength of the hinge, and I don't like that the door is not properly retained.

If their was a quick release pin or some form of positive retention so the door couldn't lift off without another step being taken like a pin pulled or something I would be happy.


I know it doesn't make much sense when I am happy to drive with no doors, but with no doors you know exactly where you stand.

Steve.
[quote="greg"] some say he is a man without happy dreams, or that he sees silver linings on clouds and wonders why they are not platinum... all we know, is he's called the stevie.[/quote]
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