After a couple years of nursing this door along, the weld finally let go. It seems that the hinge is welded to the door skin at each end then in between the hinge is stuck to the door skin with double sided tape. Over time, the tape begins to let go and the door skin starts to rub on the belt line time, this putting pressure on the welds. I have the door pictured, which completely broke, and another where the weld has just started to crack.
Has anyone dealt with this? The only option I can think of is having it re-welded, which will surely damage the paint, but I’m still left with the double sided tape problem. Doesn’t seems like there is more areas to strengthen the bond by welding. Any ideas?