Reassembling the TCS doors

[Kendo]

I didn't take any pictures. But the Banks hinge is basically a headed bolt with washers on both sides, and a nut. The abrasive washers go between the washers on each end and the bodywork. The abrasive washers need to be modified, with a hole big enough for the bolt to pass through. I found the best way to cut through the diamond grit side of the washer was with a panel punch of the right size. https://www.harborfreight.com/knockout-punch-kit-10-piece-60575.html I tried chucking a washer in my lathe and cutting the circle. But I just ground down the bit. It turns out diamond cuts better than carbide

[BDA]

I can’t help with where to put abrasive washers. I just thought I’d just interject that I don’t use them on my car and I haven’t seen the need for them. Maybe I’m missing out…

[Kendo]

You and others have mentioned that. So at first I assembled the hinges with no abrasive washers. Still used the brass washers that came with the hinges of course. But I could not successfully adjust the doors. Either the hinge was bolted down tight enough to not move at all, or it slid around uncontrollably. I couldn't find a middle ground. Maybe it has to do with the slickness of the clear coat I used. Would it have worked if bearing against the metal of the door bobbins? I even roughed up the brass washers with 36 grit sand paper. It didn't work until I used the abrasive washers, and then it did. That's only my experience. Obviously it can work without the abrasive washers too.

[Clifton]

 I have Banks hinges but didn't use washers. Just the brass nuts on the doors. I too wasn't sure if I was missing something. I don't like the brass rotating in the aluminum bobbing. I thought maybe the washers would force the hinge to rotate inside instead.

I used diamond blades (wet tile saw) everyday for 30 years. I can confirm diamonds cut through anything.

[BDA]

Maybe some course sandpaper might be helpful.

[GavinT]

Below is another stolen pic of the method I used - washers cut from a drywall sanding sheet.
My impression is that using a finer grit is better. The previous course grit abrasive washers made from grinder discs just seemed to crush the abrasive chips.

The diamond cut-off disc idea sounds perhaps better, I reckon. The trick might be finding ones with the plain steel centre section which can be drilled out easily.

I doubt there's anything that will stop the hinge pin rotating in the bobbin.
I think it was Brian? (EuropaTC) who showed a method of constraining relative movement of the stock single piece pin.
I'm not familiar with the Banks hinges apart from pictures but they appear to actually enforce rotation of the pin(s). Is that correct?

[Clifton]

The abrasive in that pic looks like drywall sanding screen.

[TurboFource]

It is Clifton