Door lugs

[kolls]

We'll I decided to try and make a set of door lugs . Here is what I used
1. Door lug guides
2. Piece of plywood
3. Vice
4. Some fiberglass resin
4. And not but least PAM . Yes the PAM you use on your skillets

[SunnySideUp]

Seems like a lot of work. Won't the plywood swell and contract throughout the year and change the fit? I know the typical rubber lugs (or after market plastic ones) that came with the car wear out and disintegrate. Have you looked at the ones that Allisons' Automotive has available? They are made of delrin (type of nylon) that will probably last longer than the car and the package comes with new fasteners, too. I've had the delrin lugs on my Spider for a couple of years and they work great. Considering that time equals money the delrin lugs are a far less expensive (and easier!) solution in my opinion.

[kolls]

I used the door lug guides as molds to make them from fiberglass resin . I took the door lug guides and sandwiched a piece of plywood between them and sprayed the inside of the door lug guides with Pam and then poured the fiber glass resin. then drilled and counter sunk the holes .

[azruss]

did you use laminating resin or casting resin. Laminating resin will crack right away in this application. They both will be brittle. Delrin, nylon, UHMW are all easily attained plastics where you can make you new ones after your polyester ones fail.

[oldflyer]

I had to make the lugs. had a small piece of 3/8 in. thick vinyl that was scrape from a basketball flooring in the gym.
can cut easily with sharp knife and seems to do the job.

[fiat218]

Can't buy some? Or what

[kolls]

Actually it's polyurethane resin not fiberglass resin. We use this at my work uraseal makes it. Worked really well. Most of the new ones u buy are plastic and break overtime and if I can save myself 20-30 dollars but for me it's not about that it's the challenge. And most important spending time in the garage instead of being in the house

[profcucchi]

I was told by a Fiat restorer that the lugs are un-necessary because as the door sags, they'll make it worse.

Anyone know this to be true?

[kolls]

That would not be true because the door lugs help keep all the weight off the hinges and tearing more

[So Cal Mark]

the lugs prevent the door from sagging. I can't imagine anyone familiar with Spiders suggesting they're not needed. They must enjoy welding up cracked doors

[profcucchi]

the lugs prevent the door from sagging. I can't imagine anyone familiar with Spiders suggesting they're not needed. They must enjoy welding up cracked doors

Thanks, Mark.

The more I think about this mechanic, the more upset I become. This didn't help.

[profcucchi]

I'll get new lugs next year, but I quickly made one out of thick, reasonably hard rubber. Once I painted it red, like the one I have, the door works well.

A quick fix, but better than being told by my former mechanic that it's not necessary.

Thanks all.

[fiasco]

Best DIY solution I've heard of is to cut them out of hockey pucks on a band saw.

http://fiatspider.com/f08/viewtopic.php ... key#p64526

-- se

[So Cal Mark]

but that ruins a good hockey puck