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[Webby the Bear]

Hi guys.

Passenger front door. Opening door and I get large cracking sound. I've had this before and I swapped out the bushings and still no difference. It's definitely coming from the other end of the strap (i.e. Inside the door).

Does one replace the strap and all good? Is it a door card off job? Any info you could give me would be great as I've never removed one before 

[grifter]

I changed one on a senator and it was just 2 bolts inside the door frame, where the strap goes. Didn't need to take door card off just the little pin that holds strap to door pillar. Would imagine omega much the same. A point to note  the door catch was on the wrong way round, it still actually worked but as the lever has a slight bend on it to follow the arc of the door momement it made the opening very clicky, stiff and noisy.

[steve6367]

Hi guys.

Passenger front door. Opening door and I get large cracking sound. I've had this before and I swapped out the bushings and still no difference. It's definitely coming from the other end of the strap (i.e. Inside the door).

Does one replace the strap and all good? Is it a door card off job? Any info you could give me would be great as I've never removed one before 

It is likely that the welds on the door end have failed, there is a repair kit you can get from VX which I have used successfully on mine.

[Webby the Bear]

Thanks for replies guys.

I'm a touch confused though. Two 8mm bolts or welds broken? And how is access gained? Through the hole in the door the strap comes out of 

And if getting it from Vauxhall is the way forward I'd rather just swap it for another door 

[Andy B]

Thanks for replies guys.

I'm a touch confused though. Two 8mm bolts or welds broken? And how is access gained? Through the hole in the door the strap comes out of 

And if getting it from Vauxhall is the way forward I'd rather just swap it for another door 

The actual check strap feeds through the front edge of the from the inside,  so yes, the door card needs removing (there's a guide somewhere).
It's the metal where the check strap bolts that cracks ..... not a weld.  The fix/bodge that Vauxhall eventually came up with was to sandwich the cracked metal on either side. You can't get your head in to look at the front edge of the door where the strap pokes out, but I'm sure a photo will reveal what's failed.
The original fix was to drill out the spot welds of the whole plate where the check strap bolts ...... I guess that cost to fit though.

[Andy B]

The small rectangular hole is where the check strap pokes through & obviously the holes either side are for bolting it to the door. The cracks appear around this small area. You could easily make the reinforcing plates yourself ..... I did.

This is the plate that Vauxhall originally used

[biggriffin]

The small rectangular hole is where the check strap pokes through & obviously the holes either side are for bolting it to the door. The cracks appear around this small area. You could easily make the reinforcing plates yourself ..... I did.

This is the plate that Vauxhall originally used

 

That is the repair panel, if the check strap has pulled thro, there is also the reinforcing plates, which there is a guide for with part numbers.

[Andy B]

.... 

That is the repair panel, if the check strap has pulled thro, there is also the reinforcing plates, which there is a guide for with part numbers.

I know it's the repair panel  but guess that the vast majoriy of cars have been repaired using the reinforcing plates

[neil74]

The one on the drivers door of mine has torn out and was lying in the bottom of the door in the way of the window.  the metal needs straightening out etc but I can get a good enough access with a hammer to take a swing at it so it will stay as is.

[Webby the Bear]

Andy. Legend thanks for explaining that, much appreciated 👍👍

I've removed plenty of door cards so I'm sure I can get my omega one off. 👍

BUT. Please forgive my stupidity......

With door card off will I be able to fit this repair panel in. I presume it bolts to the back of the original plate and therefore making the original one redundant it still there in place.

Sincere apologies if I've misunderstood 👍👍👍

[Migv6 le Frog Fan]

Easier to bung another door on there if you can easily get one in rare star silver. 

[Doctor Gollum]

Andy. Legend thanks for explaining that, much appreciated 👍👍

I've removed plenty of door cards so I'm sure I can get my omega one off. 👍

BUT. Please forgive my stupidity......

With door card off will I be able to fit this repair panel in. I presume it bolts to the back of the original plate and therefore making the original one redundant it still there in place.

Sincere apologies if I've misunderstood 👍👍👍

The repair panel gets held up to the door, marked around, old cracked area gets cut out and repair panel gets welded in its place

The alternative reinforcing plates simply bolt up where the check strap is mounted using longer bolts to allow for the extra thickness

[Webby the Bear]

Oh f..k that! Who has a door they can sell me?

[Andy B]

Andy. Legend thanks for explaining that, much appreciated 👍👍

I've removed plenty of door cards so I'm sure I can get my omega one off. 👍

BUT. Please forgive my stupidity......

With door card off will I be able to fit this repair panel in. I presume it bolts to the back of the original plate and therefore making the original one redundant it still there in place.

Sincere apologies if I've misunderstood 👍👍👍

What Doc Gollum says ...... though I thought they drilled the spot welds out of the old one & removed it completely 

[Andy B]

Oh f..k that! Who has a door they can sell me?

Just fit the enforcing plates ...... it's  plenty good enough. There's a good chance a 'new' door will be the same as yours.

http://www.omegaowners.com/forum/index.php?topic=90510.0

[Webby the Bear]

Ok thanks Andy. So instead of that whole panel I simply need this bodge kit from Vauxhall

[Andy B]

Ok thanks Andy. So instead of that whole panel I simply need this bodge kit from Vauxhall

Yes. But they're easy to make yourself from a bit of scrap plate.

[Andy A]

Ok thanks Andy. So instead of that whole panel I simply need this bodge kit from Vauxhall

Yes. But they're easy to make yourself from a bit of scrap plate.

Do you have the dimensions of the plate so I can try and make some and do you have the size and length for the replacement bolts needed?

[Webby the Bear]

Yeah I'm sure I've got some scrap too if anyone has the dimensions.

If I've got this correct then the holes in the plate will be tapped ready to accept the bolts?

[Doctor Gollum]

Yeah I'm sure I've got some scrap too if anyone has the dimensions.

If I've got this correct then the holes in the plate will be tapped ready to accept the bolts?

Nope... the bolts go into captive nuts on the check strap assembly.

Kit contains longer bolts because the reinforcement plates are 3/8" or so thick... times two and that makes a lot more than sheet steel for the original bolts.

[Webby the Bear]

Right thanks DG. Having looked at a check strap online (never even seen one off the car before) you have the plate that's part of the check strap with captive nuts.

You then fit a repair plate in front of that.

Then refit to car and the check strap with bodge plate fits up against the metal plate which is part of the door.

Then another plate in front of that.

Is that right?

[Doctor Gollum]

Yep. Door shell sandwiched between the two reinforcement plates, bolts through from the outside and check strap assembly inside...

[Webby the Bear]

Ok now I got it. Thanks all for the replies 

[Webby the Bear]

Are the reinforcements plates roughly 5mm thick each? If so I'll make some as I'm sure we've got some thicker metal knocking around 

And some shaved down cam cap bolts  as I have shite loads of them  assuming they're same thread of course

[steve6367]

Are the reinforcements plates roughly 5mm thick each? If so I'll make some as I'm sure we've got some thicker metal knocking around 

And some shaved down cam cap bolts  as I have shite loads of them  assuming they're same thread of course

If it make any difference to your thought process the kits is readily available form VX and cheap.

[Webby the Bear]

Are the reinforcements plates roughly 5mm thick each? If so I'll make some as I'm sure we've got some thicker metal knocking around 

And some shaved down cam cap bolts  as I have shite loads of them  assuming they're same thread of course

If it make any difference to your thought process the kits is readily available form VX and cheap.

Yeah was just reading the thread. For the sake of five notes I'll get them from Vauxhall 

Cheers everyone 

[Andy B]

Yeah I'm sure I've got some scrap too if anyone has the dimensions.

If I've got this correct then the holes in the plate will be tapped ready to accept the bolts?

Nope... the bolts go into captive nuts on the check strap assembly.

Kit contains longer bolts because the reinforcement plates are 3/8" or so thick... times two and that makes a lot more than sheet steel for the original bolts.

How thick? 

[Doctor Gollum]

Mince thick...

[Webby the Bear]

Big praise to OOF. Called dick heads at Vauxhall today. They were adamant this repair kit was unavailable...... til I have them part numbers from the guide Andy posted.

Now got repair kit en route for 6 pound summat inc. vat.

Cheers oof. Legends!!!

[Andy B]

 

[Webby the Bear]

There's nothing special about these plates. Will post dimensions if anyone wants to make their own

[Kevin Wood]

That would be handy, Webby, as mine needs doing.. when I get round to it... 

[Andy A]

That would be handy, Webby, as mine needs doing.. when I get round to it... 

That would be great Webby. Mine needs doing as well.

[Webby the Bear]

No problem boys. I'll measure them when I get a chance. 👍

[Marks DTM Calib]

Think I have a few spares in the parts bin

[terry paget]

Plates are part no. 9195961 94 x 35 x 2mm mild steel with holes and slot; screws are part no. 1315557 23mm x 5 large female torx head; you will need 2 of each to repair a door. They were very cheap, hardly worth making your own. You will need to cut the corners off one plate to manoeuvre it into the door. Pic follows.

[robson]

What is the answer when the door strap starts to come away from the A pillar.I assume welding but I believe there are cables in the pillar in this area. Any other methods been tried.

[Nick W]

Plates are part no. 9195961 94 x 35 x 2mm mild steel with holes and slot; screws are part no. 1315557 23mm x 5 large female torx head; you will need 2 of each to repair a door. They were very cheap, hardly worth making your own. You will need to cut the corners off one plate to manoeuvre it into the door. Pic follows.

Even if my local parts department had them in stock, I could make two in less time than it would take to drive and collect them.

[steve6367]

Plates are part no. 9195961 94 x 35 x 2mm mild steel with holes and slot; screws are part no. 1315557 23mm x 5 large female torx head; you will need 2 of each to repair a door. They were very cheap, hardly worth making your own. You will need to cut the corners off one plate to manoeuvre it into the door. Pic follows.

Even if my local parts department had them in stock, I could make two in less time than it would take to drive and collect them.

That's is a great skill to have - I couldn't :-(

[Nick W]

Even if my local parts department had them in stock, I could make two in less time than it would take to drive and collect them.

That's is a great skill to have - I couldn't :-(

You'll need an angle-grinder, then:
Cover enough material with permanent marker to make two plates, and mark them out using a scriber(sharpened nail/screw will do)
Cut the plates to size with the grinder, and clamp them together somehow.
Drill the bolt holes.
Drill smallish(6mm?) holes for the corners of the rectangular holes
Use the grinder(dremel if you're desperate, or some handsaw) to cut the holes.
File all cut edges to a safe finish. Belt or disc sander is quicker if you have one.
Unclamp your new parts.


All this is hidden inside the door, so precision/high quality finish isn't required


That's about 10 minutes work; which is probably less time than you'd spend at the dealer just trying to order the 'proper' parts

[steve6367]

You make it sound easy, think it took me 10 minutes to get the corners off the dealer ones with my hack saw!

Based on that though I will see if I can make a copy of one during the week just for interest. 

[Webby the Bear]

Still haven't got round to doing this yet. Should be this week. What's all this about cutting corners off? Not a problem to do. But just curious why as not been mentioned before

[Andy B]

Still haven't got round to doing this yet. Should be this week. What's all this about cutting corners off? Not a problem to do. But just curious why as not been mentioned before

Not enough room in the front of the door for the complete repair plate

[Andy A]

Plates are part no. 9195961 94 x 35 x 2mm mild steel with holes and slot; screws are part no. 1315557 23mm x 5 large female torx head; you will need 2 of each to repair a door. They were very cheap, hardly worth making your own. You will need to cut the corners off one plate to manoeuvre it into the door. Pic follows.

Cut all 4 corners off and by how much?

[Andy B]

....

Cut all 4 corners off and by how much?

Have you read the guide? .....    http://www.omegaowners.com/forum/index.php?topic=90510.0

[Andy A]

Have now. 

[TheBoy]

Even if my local parts department had them in stock, I could make two in less time than it would take to drive and collect them.

That's why you need TC, so they can deliver them whilst you are having your morning rituals

Although in this case, why you wouldn't make them, I have no idea. Assuming people have tools and suitable plate.

[Webby the Bear]

Not bumping this thread... just updating it for info if anyone has the torrid time I had!

So got the door card off (never had mine off before but unbelievably easy). Speaker out. Check strap out. Cut the corners of all of the repair plates (I know you don't have to but I did for good measure). I then superglued the inner plate to the check strap so the bolt holes lined up easy. Inserted check strap in then.......... couldn't get the bolts to go through for toffee.

Got a mirror in there and to say "the metal had broke away" was an understatement. It had all bent and folded in on itself 😩

Sooooooo. For me simply bolting this repair kit on didn't work.

With the help of a colleague we popped the door pins out. Disconnected electrical connection and took the door off. Laid it on some old tyres.

My man then started to unfold the mess that was left with needle nose pliers to bend it back in to reasonable looking shape. He then bolted the repair plates, check strap etc. And this pulled it even more back in to shape. Undid it all. Couple of welds on the door. Bolted it all up again. And then welded the plate in as well for good measure.

I then emptied a can of white grease all over it (as I had done with the check strap innards). He left me to put the door card back on and all was well with the world. I bought him a sausage roll and crisps for his help (though I wouldn't if I'd known that at 5.35 the next day he was going to rope me in to balancing his wheels for him  ).

Just telling you guys all this to let you know that these things don't always go rosey!!! 

Now door opens and shuts nicely.

[cam.in.head]

 bet if everyone went out to look at there door now many would be just starting to split.probably just hidden under the bolts but starting nontheless with no noise symptoms yet.remove bolt,quick spot weld and dremil could save anything worse happening for years. checked mine last week. both ok .checked my brothers .just starting on one bolt hole. sorted. preventative maintenance.

[frostbite]

I just stuck huge washers and longer bolts on, held on now for 2 years, I did try the repair plates on my estate but it didnt work so well, thats when I started with the washers

They also worked on my v70

[TheBoy]

Had it been like it for a while Webby?

If so, probably a warning to others to get the repair kit on as soon as it happens (and if its not just the bush), else it can become more involved as you say

[Webby the Bear]

TB...

It happened a couple of days before I started this thread mate (so approx. end of May).

I then have opened the door only a few times (as least as possible).

Maybe those few times were enough to make it worse 

Or maybe make this a preventative maintenance item 

[robson]

stopped my cracking by fitting a new plastic washer. Does this mean that I have no other problems in that area or is fitting the new washer a short term cure.

[cam.in.head]

the new plastic washer stops or helps the jolt when door opens and closes but is a different issue in itself realy. worth looking behind the bolts on the door part to see if its starting to crack

[Webby the Bear]

stopped my cracking by fitting a new plastic washer. Does this mean that I have no other problems in that area or is fitting the new washer a short term cure.

Like CIH says, there are two different issues. If the plastic bush is shot. Then replacing it will fix the issue. If a new plastic bush does not fix the issue check out the torrid time I had in this thread 

[robson]

thanks for the replies looks as I might be Ok but I will look for cracks

[Andy A]

Does anyone have a photo of the plastic bush and where to locate it?

Can't seem to locate one on mine.

[TheBoy]

Does anyone have a photo of the plastic bush and where to locate it?

Can't seem to locate one on mine.

http://www.omegaowners.com/forum/index.php?topic=90525.0