I checked today, no cracking but I can detect a very slight looseness of the hinge. I'm assuming pin in gudgeon play.

I'm not ready to pull the door, press the pins, ream the gudgeons, and make a new oversized hardened pin quite yet. I'll try shimming the hinge mounts to take up the play.

Alistair 

> On Feb 16, 2015, at 10:28 AM, Stacy Schneider <vwcrewman@COMCAST.NET> wrote:
> 
>     Check the metal around the door hinge. Chances are that the sheet
> metal is cracked ,both of my Vans have had the doors replaced because of
> cracks on the door .
> 
> 
> 
>    stacy
> 
>> On Mon, Feb 16, 2015 at 8:22 AM, Alistair Bell <albell@shaw.ca> wrote:
>> 
>> Hi,
>> 
>> Thanks to all who responded. I'll see if I can enlist some help so I can
>> examine hinge closely when some force applied to latch end of door.
>> 
>> Maybe I can detects hung pin movement, maybe not. I did find part number
>> for hinge pin ( used in other vw models too)
>> 
>> 321831421
>> 
>> 
>> I'm not keen on pin replacement.
>> 
>> I'm hoping maybe shimming mount plate will work.
>> 
>> 
>> Oh I know my van flexes, you can easily see that if you lift van by front
>> jack point and open front door.
>> 
>> Thanks again to all,
>> 
>> Alistair
>> 
>>> On Feb 16, 2015, at 7:43 AM, Dennis Haynes <d23haynes57@hotmail.com>
>> wrote:
>>> 
>>> If the hinge pins are worn that is the first step. They can be a PITA to
>>> press out and replace. As these vans age it is often the bodies that are
>>> flexing enough to cause the doors to go out of alignment. It gets more
>>> obvious when jacking up one corner or even putting the van on a lift.
>> Next
>>> adjustment is to try to tweak the hinge mounts or se shims. Shimming a
>> door
>>> is a bit of an art. Start by removing the door striker and shim the door
>> to
>>> close and be where you want it. Then reinstall the striker and align to
>> the
>>> new door position.
>>> 
>>> Dennis
>>> 
>>> 
>>> -----Original Message-----
>>> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
>> Of
>>> Alistair Bell
>>> Sent: Monday, February 16, 2015 1:00 AM
>>> To: vanagon@GERRY.VANAGON.COM
>>> Subject: Front door adjustment question
>>> 
>>> My drivers side front door has a little bit of sag. It feels like it
>> comes
>>> off resting n the latch when opened. I have adjusted front doors a few
>>> times, and I understand the adjustments allowed in the system. But what I
>>> need is sort of like shimming the hinge plates or getting new hinge pins.
>>> 
>>> You know what I mean? As if the hinge pins are loose enough to allow a
>>> little drop when door opened.
>>> 
>>> It's a very little amount right now, but I'd like to deal with it. Does
>>> anyone understand what I am trying to explain and have a solution?
>>> 
>>> Thanks
>>> 
>>> Alistair
>> 
> 
> 
> 
> --
>   1989 Swedish Tristar with Aluminum gates and Atiwe 16" Wheels.
>    Oldest son is an Eagle scout.