Bad door check and small crack in door

I heard a clicking in my door a few months ago. Eventually I tightened the bolts on my door check assembly in which one bolt just cracked in half. After that the sound would come and go but I intended to replace the part once the weather got warmer. Ordered the part today and I realized that the bottom screw which was the intact one stripped out that hole and left a small crack right above where the bolt sits. I talked to a guy at toyota today and he said I may be fine installing the new door check assembly/hardware if I use a washer to mitigate that crack. The part is on the way and I will attempt that soon.

If that does not work do you think a body shop could do something to fix that small crack? I don't want to have to replace the door/frame.

If it comes to it I would rather live with no door check and it just does not sit open than having to shell out thousands for a new door.

Thoughts?

 

One tack with an arch welder would probably do it.

 

That is true. I feel like a body shop could easily reinforce it with few tacks of weld. I will go in to a shop tomorrow to see what they recommend.

 

Damn, that sucks. A washer should do the job, if it makes you feel any better sometimes stuff is held into sheet metal like this with a stud/nut in a u-shaped slot vs. a hole. Try to get the biggest m6 washer that will fit in that spot to spread the load out.

 

Thanks for the reply. You talking about something like this maybe? https://accu-components.com/us/metr...AY_y7Z_JF_JPzyxCsUjZLfYImSo44iwoaAsRcEALw_wcB

I know its a 10mm bolt but the hole is stripped so I may need like an 11 or 12mm washer.

I'm also gonna take it to a body shop tomorrow to see if they can weld a tack in there to reinforce that crack.

 

The fastener should be 6mm thread with a 10mm head. I would shop around for the widest ( and maybe thickest?) m6 washer that will sit flat in that spot. It looks like a fender washer will fit to me. Washers come in different specs, I know the ones I keep on hand at work are not much bigger OD than the 10mm head itself, I wouldn't trust one of those here. They're cheap enough you could grab a handful of different ones from the hardware store to try, and use the best one.

 

Sounds good. The part wont be here for about 3 weeks along with the new hardware (my buddy works for toyota in parts department so he got me a discount, but lives pretty far away). In the meantime I'll see what the bodyshop says. Once i get the new part ill just take it to a hardware store and test out a bunch of different washer sizes. Fingers crossed something works in the next week weeks. If not, no more door check for me lol I dont want to pay whatever that entire door would be.

 

the body shop quoted just under $1000 to weld/reinforce that cracked area. They said they will have to take the door completely off to get to it hence the higher price tag. I told them I would likely try to just throw a washer in there for the time being and see how it holds. If it does not look good I may just pay the quoted price and get it reinforced.

 

I'd get 2 washers for both holes..

 

Yeah thats what im thinking. $5 in washers sounds better than paying $1000 for the welding job. I think the washers will do the trick. The part will be here in a few weeks and ill install then with the washer. I'll update with progress.

Worst comes to worst ill pay the 1000 for the weld job or live with no door check. Not too worried about anyone swinging it open too wide as im the only one who will ever drive the truck.

 

Sounds like they maybe didn't want to deal with it. I just went out and looked at mine and I bet I could even fit a tig torch in there with one of the super short caps on the back, still fully assembled besides the door check. You could definitely fit the tip of a mig gun in but then you'd have a raised bead to grind down. That being said I would see how the washers do.

 

Yeah I agree. They even said they can't warranty the repair because the same thing just might happen so that only reinforces that point. I have no expertise in welding, so forgive me lol. I'm hoping the washer solution works good enough. I even spoke to a welder after the I went to the body shop and he said just try to throw some washers in there. He told me he was retiring in a few weeks, so he wasn't too inclined to help lol. I'll consult with another welder after I try my hand at the washers.

 

I have a crack on one of those holes on my GX470 door. I put a washer on it when I discovered it 6-7 years ago, and I don't think the crack has grown at all since then. I wish I still had the original pic.

 

Thanks for the reply. This gives me hope.

 

the difference between a body guy and a repair man are leaps and bounds. repair men make it work. it might be ugly, but it'll work. body guys return it to looking factory. that means welding, sanding, repainting.

you're probably better off talking to something like a muffler shop instead of a body shop for that reason. they'll have welders, and are used to working on thin metal. of course the work won't be guaranteed, but you could probably convince them to do it for a 6pack of beer on their break at the cheapest.

 

JB Weld a washer to the door.

 

Yeah you're right. I have a buddy that probably knows a lot of people like that now that you say it. I'll give him a shout.

 

Will definitely consider this. Thanks for the reply.

 

I wouldn't recommend this option over just installing a washer over the crack.

Jb weld will flow into the crack, and if it ever needs further repair, like welding, will make it far more difficult to clean out and get a proper weld.

 

Noted. Thanks. Will try just the washer trick first before anything else.