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Old 06-24-2008, 11:10 AM   #1
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1966 17' Caravel
Silverton , Oregon
Join Date: May 2008
Posts: 31
Caravel door alignment

I haven't been able to find anything in the forum on this. Our 66 Caravel has the door with one big hinge. (Seems maybe the one-hinge door was only around a few years, and only on the Caravel?). The door is out of alignment. It still shuts--with some force--but doesn't match up very well. It seems to have "sagged"--i.e., closing side is down an inch or so. It overlaps the body on the lower left, and has a wider gap than it should at upper right. Stioll seems to seal, though there is water damage to the floor at entrance that I suspect is from leak at the door. There is "play" (slop) in the hinge if I lift up on the door. Any tips/advice, etc. on how to align? Thanks!
Mark
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Old 06-24-2008, 11:36 AM   #2
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1967 26' Overlander
albuquerque , New Mexico
Join Date: Aug 2007
Posts: 96
67 Overlander

Has the big hinge as well. Mine has had the pin replaced, because its not stainless and I am getting some oxidation on the hinge. Door works ok, but several replaced rivets indicate there was once some problem. I know you can get a replacement pin but am interested in the responses here before I go through the process to ensure good alignment.
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Old 06-24-2008, 12:04 PM   #3
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1965 17' Caravel
1983 27' Excella
Walnut Grove/Laguna Woods , California
Join Date: Jun 2004
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Our 65 Caravel had the same problem. I found that the pin was stuck in the part of the hinge attached to the door, and so the pin was turning in the part of the hinge attached to the coach, and had worn those holes to the point where the door fit almost as bad as yours. Oil holes had been drilled in the hinge at every point on both sides of the hinge pin, but the pin was still stuck in the door side. I removed the pin, not an easy job as it was pretty stuck, and removed the door. I tapped out the oil holes on the upper front side of the door side of the hinge, and the back side of the lower coach side of the hinge. I inserted set screws. I then put it all back together. Then I tightened all of the set screws. That placed the upper end of the pin rearward, and the lower end of the pin forward, putting the door in the middle of the opening, where it belongs. Now the door turns on the pin rather than the pin turning in the coach part of the hinge.

I don't have any pictures of this, however I am headed to the trailer this morning and will take a photo or two and post them later today.
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Old 06-24-2008, 12:46 PM   #4
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1971 21' Globetrotter
Arvada , Colorado
Join Date: May 2006
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My 71 GT has the one piece door hinge also. The hinge pin bores were wore out so I bored out the lugs and bushed the holes. the holes that the hinge mounts to on the trailer and the door are also oversized so that the mounting hardware can be loosened and the door adjusted. I gave a more detailed explanation on my thread #203

http://www.airforums.com/forums/f381...nte-26902.html
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Old 06-24-2008, 08:01 PM   #5
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1965 17' Caravel
1983 27' Excella
Walnut Grove/Laguna Woods , California
Join Date: Jun 2004
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I considered putting bushings in the hinge. That's probably the best way to fix this problem. However,,,,,,,I do not have the proper equipment to machine the hinge, and wanted to fix the problem without having to remove the hinge, if possible. The procedure I used may not work in every instance, but it sure worked for me. It's been six years now and the door is still in perfect alignment. I will say that I keep the hinge lubricated much better than the previous owner.
Here are pictures I took today. The entire hinge showing the oil holes, the front top, the rear bottom, and the fit of the door.
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