How to fix a Canopy door with broken welds

Step 1 of 34

Items needed to be placed onto a sales order per door:

PRT-003435 x 0.6
PRT-003436 x 0.3
PRT-003437 x 0.3
PRT-004200L x 1
PRT-004200R x 1

NOTE: on sales order specify model of canopy

Step 2 of 34

Remove any central locking wiring by unplugging from the door and cutting the cable ties

Step 3 of 34

Drill out all welds with a 6.5mm drill bit

Step 4 of 34

Run the grinder over the body hinge holes to make sure it is a flat edge for the new hinge to sit on

Step 5 of 34

<p>If there is a cable tray on the inside carefully grind off welds marked in red. And set the tray aside. <em><strong>This will make it easier to access for welding, if your welder can reach you won’t have to remove it.</strong></em></p>

If there is a cable tray on the inside carefully grind off welds marked in red. And set the tray aside. This will make it easier to access for welding, if your welder can reach you won’t have to remove it.

Step 6 of 34

Clean up the inside hinge holes ready for welding

Step 7 of 34

For the end holes you can use a flattened off drill bit or die grinder to remove the powder coating

Step 8 of 34

Grab the hinge that is labeled body

Step 9 of 34

Use clamps, clamp the hinge to the body in the direction on the video. Using the previous powder coating marks to line it up

Step 10 of 34

Ensure there is no gap under the top lip. Make sure it is flushed with the body

Step 11 of 34

<p>Weld the hinge through the holes. <strong><em>Ensure the weld is covering the holes because if there is a gap it will leak.</em></strong></p>

Weld the hinge through the holes. Ensure the weld is covering the holes because if there is a gap it will leak.

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Ensure not to penetrate welds into this groove of the hinge. If it does, use a cutting disc to cut in

Step 13 of 34

Paint these welds once they have cooled down.

Step 14 of 34

Weld the cable tray back in if it needed to be removed and paint this welds also

Step 15 of 34

Remove the old body hinge from the door

Step 16 of 34

If the hinge doesn't pull out remove the end stoppers. These need to be removed anyway and attached back on later.

Step 17 of 34

If the door hinge isn’t damaged please skip steps 17 - 26

Step 18 of 34

Use a cutting disc down the centre of the hinge insert

Step 19 of 34

Pull out the hinge insert

Step 20 of 34

Remove the door hinge welds but don’t cut into the door skin

Step 21 of 34

Pop the door hinge off with a hammer

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Grind off the door welds flat ready for welding the new hinge on

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Line up the new hinge on the door using the powder coating marks

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Make sure hinge is flushed with door and doesn’t bow up

Step 25 of 34

Weld the hinge to the door. Trying not to get the edge of the hinge

Step 26 of 34

If the edge of the hinge does get welded. You will need to use a cutting disc to remake the groove

Step 27 of 34

Use the cutting disc to remake the groove or to tidy up any welds that might stop the hinge from sliding on easy

Step 28 of 34

before attaching the door lubricate the body hinge

Step 29 of 34

Put the door on to the body by lifting the door up high then pulling down on to the hinge it should then make a pop. Then lift back up and it should make another pop. This means it is locked in.

Step 30 of 34

lubricate where you have welded the door hinge on

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Lurbricate the hinge insert

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Then insert into the door hinge, making sure it is the correct way like in the video. Ensure you are lifting the door high enough above the body pillar so the insert doesnt scratch it.

Step 33 of 34

Put the tabs back on the ends of the hinge

Step 34 of 34

Attach the gas struts and ensure the door is opening and closing properly