Door hinge repair apparatus and method

Abstract

Apparatus for use in repairing, and methods of repairing, a door hinge of a vehicle includes use of a substitute hinge bracket and at least one pin configured to be received through at least one opening of a vehicle frame bracket. A locking portion of the at least one pin and a locking surface that defines an opening in the hinge bracket are configured such that the at least one pin is locked in a fixed position relative to the hinge bracket when assembled. Further, another repair apparatus includes a substitute pin having an interference portion for forming an interference fit with one or more surfaces defining an opening of a factory hinge bracket.

1 - 28 . (canceled) 
     
     
         29 . A method for using a repair kit to repair a door hinge, wherein the door hinge comprises at least a vehicle frame bracket attached to a portion of a vehicle frame and a hinge bracket, wherein the vehicle frame bracket comprises a first and second opening aligned along and lying orthogonal to a frame bracket axis, wherein the hinge bracket comprises a first and second opening aligned along and lying orthogonal to the frame bracket axis, wherein the vehicle frame bracket and the hinge bracket are coupled using a first pin positioned in the first opening of the vehicle frame bracket and the first opening of the hinge bracket and using a second pin positioned in the second opening of the vehicle frame bracket and the second opening of the hinge bracket, wherein the method comprises:
 providing a repair kit, wherein the repair kit comprises:
 a substitute bracket for use in replacing the hinge bracket, wherein the substitute bracket comprises at least a first opening corresponding to the first opening of the vehicle frame bracket and a second opening corresponding to the second opening of the vehicle frame bracket, wherein the first and second openings are aligned orthogonally on a substitute bracket axis; 
 a first substitute pin for use in replacing the first pin and configured to be received through the first opening of the vehicle frame bracket, wherein the first substitute pin comprises a locking portion, and further wherein the locking portion of the first substitute pin is configured as a function of the first opening of the substitute bracket; and 
 a second substitute pin for use in replacing the second pin and configured to be received through the second opening of the vehicle frame bracket, wherein the second substitute pin comprises a locking portion, and further wherein the locking portion of the second substitute pin is configured as a function of the second opening of the substitute bracket; 
   removing the first and second pins to release the hinge bracket from the vehicle frame bracket;   aligning the substitute bracket axis of the substitute bracket and the vehicle frame bracket axis; and   coupling the vehicle frame bracket and the substitute bracket using the first and second substitute pins.   
     
     
         30 . The method of  claim 35 , wherein each of the first and second substitute pins comprises a threaded end portion, and further wherein the method comprises coupling a first nut on the threaded end portion of the first substitute pin after the first substitute pin is inserted through the first opening of the vehicle frame bracket and the first opening of the substitute bracket and coupling a second nut on the threaded end portion of the second substitute pin after the second substitute pin is inserted through the second opening of the vehicle frame bracket and the second opening of the substitute bracket. 
     
     
         31 . The method of  claim 36 , wherein the method further comprises providing a first bushing in the first opening of the vehicle frame bracket and providing a second bushing in the second opening of the vehicle frame bracket, wherein the first bushing defines an opening through which the first substitute pin is inserted and the second bushing defines an opening through which the second substitute pin is inserted. 
     
     
         32 . The method of  claim 37 , wherein coupling the first nut on the threaded end portion of the first substitute pin comprises tightening the first nut against an engagement surface of the first substitute pin or first bushing existing at a distance below and outside of the first opening defined in the vehicle frame bracket so as to prevent over-tightening of the first nut against the vehicle frame bracket or wherein coupling the second nut on the threaded end portion of the second substitute pin comprises tightening the second nut against an engagement surface of the second substitute pin or second bushing existing at a distance below and outside of the second opening defined in the vehicle frame bracket so as to prevent over-tightening of the second nut against the vehicle frame bracket. 
     
     
         33 . The method of  claim 35 , wherein the removing the first and second pins comprises:
 removing ends of the first and second pins holding the first and second pins in the openings of the hinge bracket and vehicle frame bracket; and   pushing the first and second pins out of the openings of the hinge bracket and vehicle frame bracket.   
     
     
         34 . The method of  claim 35 , wherein at least one of the first and second substitute pins comprises:
 an interference portion to form an interference fit with one or more surfaces defining the opening of the substitute bracket in which the at least one substitute pin is to be received;   a threaded end portion configured to be inserted through the opening defined in the vehicle frame bracket and the opening defined in the substitute bracket for coupling to a nut;   an elongated pin end portion extending along a pin axis at an end opposite the threaded end portion of the at least one pin; and   an engagement element extending orthogonal to the pin axis at a position between the threaded end portion and the pin end portion to maintain the pin end portion at a position to receive a door bracket of the vehicle when the nut is coupled to the threaded end portion, wherein the engagement element is configured with one or more grasping surfaces such that a tool corresponding to such grasping surfaces can be used to hold and/or turn the engagement element, and further wherein coupling the vehicle frame bracket and the substitute bracket comprises using the tool corresponding to the grasping surfaces to hold and/or turn at least one of the first and second substitute pins.   
     
     
         35 . The method of  claim 40 , wherein the interference portion is configured such that substantially an entire inner surface defining the opening of the substitute bracket is in contact with the interference portion of the substitute pin when at least a part of the interference portion of the substitute pin is positioned in the opening of the substitute bracket. 
     
     
         36 . The method of  claim 35 , wherein the locking portion of at least one of the first and second substitute pins comprises a threaded region. 
     
     
         37 . The method of  claim 35 , wherein the locking portion of at least one the first and second substitute pins comprises a knurl region. 
     
     
         38 . The method of  claim 35 , wherein the first opening of the substitute bracket corresponding to the first opening of the vehicle frame bracket and the second opening of the substitute bracket corresponding to the second opening of the vehicle frame bracket are configured differently than the first opening of the hinge bracket and the second opening of the hinge bracket. 
     
     
         39 . The method of  claim 44 , wherein at least one of the first opening of the substitute bracket and the second opening of the substitute bracket comprise a threaded region defining at least a portion thereof. 
     
     
         40 . The method of  claim 44 , wherein the first opening of the substitute bracket is defined by a locking surface having different dimensions than the first opening of the hinge bracket and the second opening of the substitute bracket is defined by a locking surface having different dimensions than the second opening of the hinge bracket. 
     
     
         41 . A method for using a repair kit to repair a door hinge, wherein the door hinge comprises at least a vehicle frame bracket attached to a portion of a vehicle frame and a hinge bracket, wherein the vehicle frame bracket comprises a first and second opening aligned along and lying orthogonal to a frame bracket axis, wherein the hinge bracket comprises a first and second opening aligned along and lying orthogonal to the frame bracket axis, wherein the vehicle frame bracket and the hinge bracket are coupled using a first pin positioned in the first opening of the vehicle frame bracket and the first opening of the hinge bracket and using a second pin positioned in the second opening of the vehicle frame bracket and the second opening of the hinge bracket, wherein the method comprises:
 providing a repair kit, wherein the repair kit comprises:
 a substitute bracket for use in replacing the hinge bracket, wherein the substitute bracket comprises at least a first opening corresponding to the first opening of the vehicle frame bracket and a second opening corresponding to the second opening of the vehicle frame bracket; 
 a first substitute pin for use in replacing the first pin, wherein the first substitute pin comprises a locking portion, and further wherein the locking portion of the first substitute pin comprises a knurl region to provide a locking function between the knurl region and the first opening of the substitute bracket when installed; and 
 a second substitute pin for use in replacing the second pin, wherein the second substitute pin comprises a locking portion, and further wherein the locking portion of the second substitute pin comprises a knurl region to provide a locking function between the knurl region and the second opening of the substitute bracket when installed; 
   removing the first and second pins to release the hinge bracket from the vehicle frame bracket;   aligning the substitute bracket axis of the substitute bracket and the vehicle frame bracket axis; and   coupling the vehicle frame bracket and the substitute bracket using the first and second substitute pins.   
     
     
         42 . The method of  claim 41 , wherein the first opening of the substitute bracket corresponding to the first opening of the vehicle frame bracket and the second opening of the substitute bracket corresponding to the second opening of the vehicle frame bracket are configured differently than the first opening of the hinge bracket and the second opening of the hinge bracket. 
     
     
         43 . A method for using a repair kit to repair a door hinge, wherein the door hinge comprises at least a vehicle frame bracket attached to a portion of a vehicle frame and a hinge bracket, wherein the vehicle frame bracket comprises a first and second opening aligned along and lying orthogonal to a frame bracket axis, wherein the hinge bracket comprises a first and second opening aligned along and lying orthogonal to the frame bracket axis, wherein the vehicle frame bracket and the hinge bracket are coupled using a first pin positioned in the first opening of the vehicle frame bracket and the first opening of the hinge bracket and using a second pin positioned in the second opening of the vehicle frame bracket and the second opening of the hinge bracket, wherein the method comprises:
 providing a repair kit, wherein the repair kit comprises:
 a substitute bracket for use in replacing the hinge bracket, wherein the substitute bracket comprises at least a first opening generally corresponding to the first opening of the vehicle frame bracket and a second opening generally corresponding to the second opening of the vehicle frame bracket; 
 a first substitute pin for use in replacing the first pin, wherein the first substitute pin comprises a portion adapted to engage with the first opening of the substitute bracket to inhibit rotation of the first substitute pin relative to the substitute bracket; and 
 a second substitute pin for use in replacing the second pin, wherein the second substitute pin comprises a portion adapted to engage with the second opening of the substitute bracket to inhibit rotation of the second substitute pin relative to the substitute bracket; 
   removing the first and second pins to release the hinge bracket from the vehicle frame bracket;   aligning the substitute bracket axis of the substitute bracket and the vehicle frame bracket axis; and   coupling the vehicle frame bracket and the substitute bracket using the first and second substitute pins.   
     
     
         44 . The method of  claim 43 , wherein the portion of each of the first and second substitute pins comprises a threaded region. 
     
     
         45 . The method of  claim 43 , wherein the portion of each of the first and second substitute pins comprises a knurl region. 
     
     
         46 . The method of  claim 43 , wherein the first opening of the substitute bracket corresponding to the first opening of the vehicle frame bracket and the second opening of the substitute bracket corresponding to the second opening of the vehicle frame bracket are configured differently than the first opening of the hinge bracket and the second opening of the hinge bracket. 
     
     
         47 . The method of  claim 43 , wherein the first opening of the substitute bracket is defined by a surface having different dimensions than the first opening of the hinge bracket and the second opening of the substitute bracket is defined by a surface having different dimensions than the second opening of the hinge bracket. 
     
     
         48 . A method for using a repair kit to repair a door hinge, wherein the door hinge comprises at least a vehicle frame bracket attached to a portion of a vehicle frame and a hinge bracket, wherein the vehicle frame bracket comprises a first and second opening aligned along and lying orthogonal to a frame bracket axis, wherein the hinge bracket comprises a first and second opening aligned along and lying orthogonal to the frame bracket axis, wherein the vehicle frame bracket and the hinge bracket are coupled using a first pin positioned in the first opening of the vehicle frame bracket and the first opening of the hinge bracket and using a second pin positioned in the second opening of the vehicle frame bracket and the second opening of the hinge bracket, wherein the method comprises:
 providing a repair kit, wherein the repair kit comprises:
 a substitute bracket for use in replacing the hinge bracket, wherein the substitute bracket comprises at least a first opening having different dimensions than the first opening in the hinge bracket and a second opening having different dimensions than the second opening in the hinge bracket; 
 a first substitute pin for use in replacing the first pin, wherein the first substitute pin comprises a portion adapted to engage with the first opening of the substitute bracket to inhibit rotation of the first substitute pin relative to the substitute bracket; and 
 a second substitute pin for use in replacing the second pin, wherein the second substitute pin comprises a portion adapted to engage with the second opening of the substitute bracket to inhibit rotation of the second substitute pin relative to the substitute bracket; 
   removing the first and second pins to release the hinge bracket from the vehicle frame bracket;   aligning the substitute bracket axis of the substitute bracket and the vehicle frame bracket axis; and   coupling the vehicle frame bracket and the substitute bracket using the first and second substitute pins.