Whew. Five hour to change a door hinge is a new record for me!
You know it isn't your normal hinge replacement job when you haul out the welder, grinder and epoxy.
The door on the right pretty much fell off its two-way hinges yesterday. It was at the end of the day and the door did still close, so I put off fixing it 'til this AM. I started at right about 10 AM and finished up at 3 PM. Of course, fifteen other things needed attention around the pub, kitchen and brewery, so maybe I didn't spend all of those five hours on the door.
Those swinging doors have been in use since the "old brewhouse" was built almost thirty years ago. They've been hit with forklifts and loaded pallet jacks, soaked all day for weeks at a time, sometimes in caustics and sometimes in beer. The door that failed is the most used, so it swings hundreds of times a day.
Which might have something to do with this:
That's what's left of the swinging hinge.
The new one looks much better:
Years ago, I had to make and install some braces to hold what was left of the door together. The lower one is partially visible in the first pic above and this is the upper one:
The upper pivot socket of the hinge mounts to that--and it's welded on. Using a cut-off wheel and AG, I cut the old welds off, ground the welds down and welded the new one back on.
Where there is still wood on the door, it was completely split, so I had to mix up some epoxy and repair that. Then drill and tap the lower brace for the mounting points of the new hinge, which is similar but not identical to the old one.
Since there is no wood on the threshold of the door, the next step was marking and drilling the concrete for some shell anchors, which was a PITA, as there is no template with the hinge so it has to be mounted to the door and marked in place, then the door needs to be removed again to drill the holes.
Finally done for today and it's beer-thirty. The new hinge is in and the door works again--but not well. I'll screw around with it some more after I finish this fine malt beverage....