Aluminium door hinges...price now added!
Turbo Mini Forums

By the looks of it you could quite easily shift 20 sets.

If something is worth doing, it's worth doing half of.

Morning Guys,

ive been working with matty modeling the proposed design for the hinges. so i thought id just update you with the progress.

The initial designs are done, SolidEdge calculates the assembly minus bolts to be 90g. i initially modeled the standard hinge and weighted it. it weighted 281g and the software calculated it to be 280g, so im pretty confident in it.
To keep cost down and as the intended use is only for lightened door (eg. ally skins, perspex, not window mech, etc) we decided against using the third bolt hold on the top hinges. this means that there wont be need to have several variations produced.

Ive ran a quick FE of the assembly, which looks promising. We intend to use 6061-T6 Ally which has a yeild strength of 274 MPa, as you will see from the FE pictures the majority of the assembly sees stresses less then 30 MPa. there are localized areas of high stress around the clevis pin under bending but this is well with in the yeild strength and shouldn't give us a problem. There is scope to optimize the assembly further.

The drafts will go out for quotation this week and we should have a price by the middle of next week.









Any thoughts will be greatly received.

1972 998 TURBO SLEEPER

Sometimes cardboard aided design is the only way lol

1972 998 TURBO SLEEPER

I'll be running slightly lightened all steel doors with ellectric windows rather than the mechanical winder. Would these be OK for me or will I just wear them out??

how much do the doors weigh? We were considering a maximum door weight of 10-12kg

1972 998 TURBO SLEEPER

Does the pin slide out ie quick release :) ?

yeah, it will use an R clip to hold it in

1972 998 TURBO SLEEPER

8.42kgs :)

the bare frame, minus glass and mechanism is 9.7kg

1972 998 TURBO SLEEPER

I might be heading down the cellar with the bathroom scales tonight then...

I like those, but can't help thinking there is scope for them to be lighter yet

Matty
Commander
Rob
98turbomini25
5portsrock
miniminor63
Paul S
MarkGTT
apbellamy
minimadamotorman
Ben h
Jimster
Star Mag
Mickey.h
stefaz
munnracing
Si P

I'll have a set. Good work men.

I drill holes in everything..!

your right graemac, but for this initial design we want a significant safety factor.

1972 998 TURBO SLEEPER

I suppose that makes sense and looking at the FEA there is very little issue.

Out of curiosity (anmd no criticism as I couldn't do this!!) - how is the loading modelled? Do you take into account the size of the door and hence the moments it will exert rather than just a shear force on the hinge face?

I am certinaly interested in a set if the price is right:
Matty
Commander
Rob
98turbomini25
5portsrock
miniminor63
Paul S
MarkGTT
apbellamy
minimadamotorman
Ben h
Jimster
Star Mag
Mickey.h
stefaz
munnracing
Si P
GraemeC

No criticism taken, as much in put from others is greatly received. the FE was performed with a simple 10kg vertical load. i was under the impression that the clamping force between the hinge face should far exceed the shear force.
but further FEA will be done with both hinges and a wireframe to simulate the bending loads.

1972 998 TURBO SLEEPER

I would expect that the door will try and tear apart the top hinge and push together the bottom one.
Wear of the hing pin holes may also become a longer term issue with heavier doors?

i can see where your coming from, ill run an FE with both hinges, they should be substantial enough to resist bending from the weight of the door, but ofcourse if someone decides to hang off it there will be plastic deformation around the pin.
wear in the pin is something ive been thinking about, i was under the impression that a soft material rubbing a hard material generate low friction. steel washers will sit between both halves of the assembly to prevent the ally binding up

1972 998 TURBO SLEEPER

Have thought about a steel bush pressed into the hinge? To stop the pin tearing through the ally if the door is to heavy?

In boost we trust

we had considered that, but as the peak stresses so fare are a lot lower than the yield strength it doesn't seem necessary. these are designed only for lightweight doors <12kg. if you are running a standard heavy door im thinking lightweight hinges are the least if your worries lol

1972 998 TURBO SLEEPER

Sorry, i only skimmed through your post before.
Atm youve got a safety factor of 7. Thats pretty damn good really.
Whereabouts did you put the load?

I would be getting a set but ive got an aussie clubman, so external hinges.

In boost we trust

the loads were applied the face of the hinge which clamps to the door. as long as the bolts are torqued up enough the clamping force shouldn't put the bolts into shear

1972 998 TURBO SLEEPER

sorry guys must add that the pictures of the hinges shows the initial design stage, i thought i would design them with out machining costs in mind get a quote and go from there, if the costs are going to be to high the design will be simplified, but i will try my hardest to keep the weight around 90g

1972 998 TURBO SLEEPER