RV Door Hinge Fix Suggestions

[SPSchaller]

My 2005 Bounder's door has a few hinges at the bottom where the tops of the pop-rivets have broken off. The hinges at the top & middle of the door are fine and the door still closes ok, but I'm concerned this may change going forward if I don't fix the bottom hinges. Does anyone know of a way to reattach these hinges? I looks like the old rivets are still in the door frame.
Thanks.

 

[Kirk]

You can drill out the old pop-rivets and put in new ones. Another possibility would be to cut off the protruding parts and then punch them into the frame, then replace with new.

 

[old RV guy]

Kirks suggestions are really the only options. You could try a metal screw with a less pronounced head or grind the heads down, but it would'nt be a long term solution and once they wallowed out you'd be "screwed". Rivet guns and rivets are inexpensive and simple to use.

 

[SPSchaller]

I kinda thought those would be my options, but some folks come up with some ingenious fixes to RV issues, so I thought I'd float the question. I initially considered using self tapping screws, but the heads would present an issue and I'm unsure what the frame around the door consists of... That said, going with rivet replacement. Thanks.

 

[TonyL]

If you look carefully at the hinges, no part of the hinge overlaps itself. You therefore have the thickness of the hinge clearance for screw heads.
A flat pinhead might fit without interfering with the door closing.
However, the previous suggestion of taking of the protruding rivets and punching the hole clear for new rivets to me is the proper solution.

 

[TonyL]

As you can see, ours has both factory fitted.

 

[Rene T]

I would use a small pin punch and drive out the center rivet pin. Then grind down the remains piece so it’s almost flush with the door frame. Then use a little bit bigger pin punch and just drive it into the frame

 

[CharlesinGA]

If you use a drill bit, use something quite a bit smaller than the rivet. Rene is suggesting doing it without any drilling at all and this is good. Just make sure of what size rivets they are and only use punches smaller than the rivet. Go slowly.

Charles

 

[Rene T]

Do not do any drilling. If the drill goes in off center, you will mess up the diameter of the rivet hole.
Using a small pin punch there is a good chance the entire rivet will be pushed through the hole. It wouldn’t hurt to spray a little penetrating oil on the rivet

 

[gwinger]

Do not do any drilling. If the drill goes in off center, you will mess up the diameter of the rivet hole.
Using a small pin punch there is a good chance the entire rivet will be pushed through the hole. It wouldn’t hurt to spray a little penetrating oil on the rivet

Using a drill bit on an aluminum rivet with a steel pin will go off center quickly.
I would tap the rivets flush with the frame before using the punch.

 

[Rene T]

Using a drill bit on an aluminum rivet with a steel pin will go off center quickly.
I would tap the rivets flush with the frame before using the punch.

Doing that may mushroom the end of the rivet. Using a small pin punch 1st, may drive out the entire rivet

 

[gwinger]

Doing that may mushroom the end of the rivet. Using a small pin punch 1st, may drive out the entire rivet

Very possible' didn't think of that. Maybe using a dremel to grind them off or cut them flush first.
I've broken many small punched in my lifetime.

 

[No cats]

You may be able to just push them in using a piece of wood, I would try that first.

 

[gwinger]

You may be able to just push them in using a piece of wood, I would try that first.

That would probably just imbed them into the wood.

 

[Rene T]

That would probably just imbed them into the wood.

The rivets shouldn’t be tight in the hole except maybe a little corrosion. You may find 0.0005” to 0.001”clearance. Like I said,earlier start out with a little penetrating oil.
I think you are going to find that they will just pop out real easy. Keep us informed please as to the outcome.

 

[No cats]

That would probably just imbed them into the wood.

I doubt that. Even if its a wood framed trailer, there is always space between the door and the framing. There needs to be space for tolerances and flexing while on the road.

And if there is wood right behind the rivets, then a flathead panhead screw would be the solution.

 

[old RV guy]

You're not likely to punch those rivets through without deforming the aluminum frame. Use a drill bit which will just snug up to the rivet without going through, but not larger than the rivet hole in the frame. The rivet will spin off in just a few revolutions of the drill bit, easy peasy.

 

[Rene T]

Harbor freight has a set of 8 pin punches for under $8.00. 1/16” to 5/16”

 

[gwinger]

The part of the rivet protruding may be expanded since it there is a hole in the bracket larger than the rivet.
Cutting that piece off would eliminate any binding.

 

[SPSchaller]

I truly appreciate all the responses. I used an awl to pop the buttons off the backside of the rivets and then using a 3/16' drill bit, which I sized using the hole on the hinge, and drilled out the old rivets. It went quite quickly. I used a straightened paperclip, with a small bend at the end to approximate the thickness of the frame and hinge, then went to Lowes and bought a hand riveter and some 3/16"(5mm) x 1/4"(6mm) aluminum rivets. The only issues I had resulted from my lack of knowledge using a riveter (soon resolved) and that I was using the largest size rivet the tool could handle (the rivet stem often got stuck in the tool afterwards). So, project complete and the door swings like new!