Projects Falcon Console door fix

So I got this console from FeeBay today. If u don't already know, these are uber expensive in even bad condition. Even though I thought this was in better shape I think I can work with it still. The problem with these doors are they always break off from the hinge. Not a very good design. IDK how it was originally attached. But someone tried to tap the aluminum and it just is not going to hold. There are tiny holes coming thru the top. Alot of these have been repaired by just drilling holes through the door and using bolts. I would rather not go that route. Since this is aluminum I think I need to take it to a pro. welder. So I need some advice, do I get this welded and if so do they need to weld bolts (minus the head) to the door and spot weld the tiny holes on the top? Or should I just go the bolts route through the top? Due to the ribs, I would have to counter sink the top so the bolts are flush. Thinking about using hex bolts.

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can you redrill the holes in the hinge and machine the threads into the fresh metal?

 

If ya want some 3M 8115 panel bonding adhesive would stick that back together..maybe take it to a local body shop and see if ya slap em a little $$ they’ll glue it together for ya..no worries about welding...and it will hold with no issues

 

I think I'll end up have the same issue, there's just not enough metal there

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That sounds like a good idea. The far left threads no longer hold, so would this hold without screws? Also they would have to get it just right as I would not be able to adjust

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Use the glue and what ever screws ya got to hold it in place..get it set and don’t touch it for a day

 

Thanks for the help

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If you decide to use bolts all the way through, I'd get stainless carriage head bolts. The smooth heads would look much better than hex heads.

 

I have two of those consoles on the shelf . One great at hinge and the other is not. I am planning on just epoxy it .

 

I should have got out of the stock market and bought up all the falcon consoles I could find.

 

Why not just panel bond the hinge to the console without any screws. After all it holds new cars together without fasteners.

 

To hold it in place..

 

That's what clamps are for.

 

Probably one of the best looking and worst engineered parts ever made. Just about every one I've seen has been repaired. Got to wonder if muggy weld rods work on them?