Reading my disassembly notebook from 2005, I see that I had noticed the door hinges had body color but not primer, and it appeared to me at that time that the doors had been hung and aligned prior to color painting. Which makes sense, to avoid damage. It’s also true of the boot lid.
Did I remember that 13 years later? Nope. I painted the doors separately because I was cramped for space and thought I could do a better job with them flat. Well, they turned out good, but hanging them is a handful of worms. I had put the center trim piece in first. Now trying to align the doors I caused a bit of damage. So I removed the center trim piece; apparently it should go on last. I was careful to note back in 2005 exactly where each shim piece went in the hinges, but the LF lower one now seems to require two shims where it had only one before. These shims are not in the SPC. They all seem to be about .050" thick. Quite a trick getting them in there. They should have provided an access slot in the door inner panel.
Now I can see how the factory boys did it. They must have had some sort of door alignment fixture that they could set the two doors on, add the shims and hinges, tighten the hinge screws, then take the two doors now hinged together and hang them on the body center pillar or B post. There is some more final alignment needed there with shims between the hinges and the B post, for which they used believe or not cut-in-half split-cotter pins, then they tightened the hinge center screws.
Most of my eight grease fittings on the hinge pins were broken off, so I extracted them and put in new ones. Easy to do with a propane torch and a screw extractor, they all came right out with no difficulty.
Now I can see why they broke off. Fling the door open and they get hit.
This doesn’t make any sense. You can’t get a grease gun nozzle on them.
I’m wondering if there should be a different kind of fitting on there instead?