Outer Limits 4x4 Board

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

Try a impact driver

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.

There a prick!

Broke 1 impact driver and got them all out except for one i had to grind off!

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.

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

use a chisle and unscrew it with the chisle works all the time

Impact driver and a BFG.
Chisel
or small flame torch head head and unscrew

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.

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

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.

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.

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

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

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.

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






how did you go buy the way

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.

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!

Cheers - Longbaser.

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.

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.

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

Steve.

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.

Those doors look familia!

They came up very well!

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

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.

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

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.