Aluminium Fatigue

Can the kit be fitted without spraying?

i would like to know as well as mine are not cracked but i would like to keep them that way and would consider fitting the kit as a precaution to preserve my originality but would not want to go spraying a part that is seen. I had what i thought was a crack but it turned out to be some kind of waxed paper packing behind the actual hinge. Very strange.

I have also noticed two things:
1) that the doors do definately have alignment marks which may be weak points for the cracks to start from.

2) that some cracks seem to be consistant with the door being pulled upwards at the lock end, possibly due to some alignment problem. I know that my doors have always sat out too far from new and that has maybe saved them from this problem. I have also readjusted them on one occasion when i got the car because they didnt shut properly.
 
Colin said:
As part of the repair was it neccesary to have any part of the door resprayed??
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Not the door. But the new hingue.

But scince the repair kit is not available yet, I don't believe there is the repair kit installed, more think these are the new doors...
 
I talked to the mechanic that will be installing the kits for me, and from the information he gave me, they will install a plate inside the door and one on the outside. The crack is left as it is. I forgot to ask how the plate on the inside is supposed to be attached to the door, though. What amazes me is that the plate on the outside will as I understand be visible but he claimed nothing is supposed to be painted. It seems from Erstens post that's not the case. We'll see. Anyone with the repair bulletin in hand that can verify what exactly is supposed to be done?
 
No disrespect to Xiter but if that is true
what a crap fix
it is literally the aluminium equivalent of papering over the cracks!
A total bodge
disgraceful
OK for me whose doors have not cracked yet but wholly inadequate for all owners unfortunate enough to have cracked doors already
 
Yeah you are right.

If I remember its a cosmetic issue and not structural, so its only a cosmetic fix. TBH I can't see what most people are rushing to sort it for, unless you intend to sell your car in the next few months. Surely this isn't timed constrained to the 2-3 months after the work around becomes available, so why run to the dealer for a problem we are blowing out of proportion.

If we had a 1-2mm hair line crack under the car that wasn't structural we would all never know lol. But as it gets pointed out, we seem to find it and panick. Don't we have a 10 year corrosion thing? Or is this completely separate, and needs to be done asap?
 
They actually remove the door from the car, route out the metal from around the top hinge back to non-cracked aluminium and then bond a new reinforcement plate inside the door and attach the new hinge assembly on the outside and re-attach the door.

The new top hinge and plate need painting, as does the area around the routing.

Cheers,

Mike
 
Thank you Mike. Apparently the mechanic didn't know what he was talking about.
Does the repair bulletin specifically say they should route out the metal from around the top hinge back to non-cracked aluminium?
 
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Emm said:
Yeah you are right.
I can't see what most people are rushing to sort it for, unless you intend to sell your car in the next few months.
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I am what I am. I like to keep my car in perfect condition. If I know about a problem, the natural thing for me is to fix it, no matter if it's a stone chip or a cracked door. It's just a matter of principle to me.
It makes me feel better.
 
Xiter said:
Thank you Mike. Apparently the mechanic didn't know what he was talking about.
Does the repair bulletin specifically say they should route out the metal from around the top hinge back to non-cracked aluminium?
Click to expand...

I've not seen the actual repair procedure, but there is a limit to what can be removed, as the reinforcing plate is only so big.

If the crack has extended beyond this, then I'd imagine the door would be replaced.

Cheers,

Mike
 
I know mate, I understand, but 28 pages and 256 replies about a 1mm cosmetic problem lol. In some ways the ARB issues are far worse. My car has failed 2 MOT's in 2 years due to ARB bushes , with all bushes fitted at Audi and we are getting stressed about a 1mm hair line issue that most wouldn't know about if it wasn't for the use of the internet. However you will know about the ARB every MOT for the life time you have the car...

Anyway i hope you get it sorted:)

I will stop banging the bees nest with the stick now:D
 
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door repair

It looks to me as if audi wakefield have done exactly what skipton has written earlier.
I did want the repair done because the driver's door didnt sit 'right' in the frame and as you looked behind in the wing mirror you could see the extent of the poor fit along the edge of the window strip where it met the front edge of the window strip from the rear door.
It was also annoying that it took a couple of shoves to close the MF
 
why do we think that a travelling crack is "cosmetic" ?
if the door sits on the hinge and the metal the hinge is attached to is cracking then at some point the door will just drop so you cant close it properly. As the crack gets larger the purchase the swinging door has on the end of the crack gets progressively more. this isnt cosmetic
this happened on another old car i had which had steel doors so i know it isnt just a cosmetic problem.
I fix cracks for a living and one thing i would say for sure is...
they never get smaller!
 
I've just noticed one of my doors possibly has a mm or two crack but I'm in no immediate rush to go to Audi. Whilst I agree that if the door doesn't close or is out of alignment then it needs rectifying a.s.a.p., for those like me at the very early stages I'm inclined to be cautious rather than have body work repairs.

I recall (correct me if I'm wrong) that the repair requires the door to be resprayed. Can a paint shop re-spray be as good as the original factory job? Based on pass experience (non-Audi) I have my doubts.
 
d4v1d sm4rt said:
if the door sits on the hinge and the metal the hinge is attached to is cracking then at some point the door will just drop ...
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No. Look at my images on page 11. http://www.a2oc.net/forum/showpost.php?p=55808&postcount=209
The weight of the door is not given to the hingue by the sheet metal visible around the hingue.
Behind the outer sheet metal, there is a thicker one on the inside!. And this allocates the forces.
And no one has a longer crack than 10 or 12mm.
So if there is no one in the world with a crack longer than 15mm, so the door will never fall off.
But I agree that it is not what it should be and Audi should fix it.

Your car with steel dorrs will not have a thicker sheet metal on the inside not visible for you, I would guess.
 
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HI all

Just took a look at my car, and I have cracks aswell, what do I do, do I need to speak with AUDI about it, will they fix it for me

I have tryed to read all these post but there are just to many, so all I need to know is what do I have to do

Thanks Colin
 
Door Repairs

Took my car to local Audi garage today for door repairs, Despite being booked in 3 weeks ago one part still on back order. So looks like a case of supply and demand. Garage was very good and tell me they will ring when parts arrive

Steve
 
steve hughes said:
one part still on back order.
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The German driver side (so your passengers side) hingue is not available yet!


And I heard that there will not be cut out any metal from around the top hinge back to non-cracked aluminium.
But there will be mounted a sheet metal as a cover and inside, the outer sheet metal (actually the door itself) and the sheet metal behind it will be bond together with Epoxy.
 
Just got a call from my local dealer (aylesbury) and they have booked my car in for repair.....going to take about 4 days in total....will keep posted with results/pics.

Matt
 
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