Well well well. The end is near - to putting a screen door on Madge.
A year ago I began a quest to put a screen door on the Caravel
. I searched high and low and finally found a used screen door, but it had no hinge. Months later I found the hinge and pin. Then I began removal of the existing pin. I followed the instructions at VintageAirstream.com, as I did successfully with our last vintage trailer, which had an awful squeak. But the damn pin would not budge.
The first issue was the roll pin. There appeared to be a roll pin in the hole, APPEARED. Turns out that it was two ends of a roll pin sticking out of each side - with a broken off drill bit inside. With a bit of blood sweat and tears I got it out. After DAYS. Dremel, drills, punches, chisels...
Only to discover that sometime in the past someone had actually drilled the main hinge pin IN HALF, two pieces, when the drill bit broke on them. Thats hardened drill bit and 2 stainless steel hinge pin halves. Not only that, but they apparently BEAT the pins from each end until each half of the pin INSIDE the cast aluminum hinge casting was mushroomed where they met. Meaning they were locked-in at the point of the roll pin hole.
After more DAYS of frustration, I elected to use a cut-off wheel and cut the hinge in several places between the castings. I got the door off. Leaving the two halves of the pin locked in the center casting. I used a dozen Dremel tool bits with diamond coatings and a vice grip to rotate the pin while grinding off the widened/mushroomed "head" through the roll pin hole. Took FOREVER.
FINALLY the two pin halves came out of the casting, TODAY! Leaving a pin remnant in the top casting of the door which was also mushroomed from being beaten in several attempts to get that damn hinge off by both me and whomever in the past. It had to be beat out using the new hinge pin from below, while laying on the grass. But with the help of a vice grip locked onto the pin and a hammer and new hinge pin I beat it back out! Yay!
Now to install the new screen door hinge…