I just bought a used 2004 F-150. The driver's side door opened so far that the hinges contact the outer door skin. The damage is hardly noticeable at this point, and I am trying to fix it. I purchased new hinges, hoping that the original hinges had just been tweaked to the point where they made contact. That does not seem to be the case. Upon close inspection it appears that the door side hinge mounting point has actually cracked, allowing enough extra flex that at full swing the door skin hits the hinge.

Has anyone else ever seen this? Anyone ever repaired this? My first guess is to remove the door and tack weld where the cracks are located to eliminate the extra flex. Anyone have another opinion? I sure would appreciate it.

 

I would lay a nice bead down on that crack and then grind smooth.... That must have been one heck of breeze to crack the metal like that.... Usually steel bends

If you take a picture of the crack and the damage on the body that would prob help with any more ideas.

 

All fixed! I bought new hinges, but that did not seem to be the problem. I ended up cutting some large shims out of 1/8" thick flat stock, in a pattern to fit between the hinges and the door. Not only did this move the door skin 1/8" further away from contacting the hinge, but it also stiffened up the door area. Now the door can open to full swing with no issues.

This is something that they should do at the factory. The door is heavy, and re-alignment is a bit annoying, but it is way better than having those hinge bite marks in your door edge!!!