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How to re-hang a garden shed door?

BigFella1956

Hello Everyone!, I have a steel garden shed, 6m X 3m. Today, the left opening door (when looking front on) was caught in strong wind and the door was almost ripped off its hinges of which there are 3 in total with each secured by 6 rivets - 3 into the door frame and 3 into the shed frame. I have an idea or 2 how to fix, however, I thought I'd see if the Workshop Universe could make any recommendations that I have not thought of. See 3 pictures below. Regards, Chris

Shed 3.jpg Shed 2.jpg Shed 1.jpg

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Doors and Windows

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EricL

Hello @BigFella1956

From an anchoring point of view, I suggest changing the rivets with Zenith 1/4" x 12mm Zinc Plated Mushroom Head Bolt And Nut on the condition that it will not interfere with the operation of the shed door. Although the mushroom heads are low it will take up more space than blind rivet heads. You might need to do a bit of an adjustment with the hinges to make it work.

Let me call on our experienced members @Dave-1, @MikeTNZ, @TedBear and @JoeAzza for their recommendation on what to use on your shed door.

If you have any other question we can help with, please let us know.

Eric

MikeTNZ

Hi @BigFella1956,

My advice would be to get a 2.5-3mm thick steel plate and rivet or bolt it in position and also build up the fixings to the hinge.

I think that machine screws and nylock nuts would probably be better than any rivets as these tend to pull out with any lateral force on them.

If you require any further help, by all means let us know.

Cheers,

Mike T.

TedBear

From the pics it looks like the head of the rivets were on the shed side and the hinges held on only by the spread of the rivet ...?

After some panel beating or repositioning of hinges, I'd be using the biggest pop rivets that will go through the hinge holes, attaching them from the hinge side and using a small washer on the shed side to give the rivets some decent metal thickness to pull against. If you can fit bolts and nuts instead, as suggested by EricL then that could be a good solution.

Dave-1

Good Morning @BigFella1956

Bugger! Yeah we have all done the same and the wind will take it and run. 😕

The post of the door looks solid still which is good, I went over the photos a few times trying to figure out what might be able to done.

How about replacing the rivets on the hinge (larger if the holes have been expanded due to the wind or elongated.) If its too far elongated maybe a new set of holes will be needed on the post. With the door side, Id buy some metal strapping and cut it so it will fit into that cavity strip wise (the white colourbond U channel) The smallest strapping I could find was 25mm in width or you can buy a gal sheet and cut it down)

Make the new "back" strip at least 3times as long as the hinge. Pop rivet to the location of the hinge part of the door at the very top and bottom parts so its locked into place then when you go to re-attach the hinge itself go through the white metal and the strap itself. That way you are re-enforcing that edge.

Id also add a chain phyisically to the door top or mid to the point the door can open out. That way the wind cant collect the door/s next time.

Dave

BigFella1956

Thanks Dave. Yes, it will be important to reinforce the area. As for the chain, bl**dy good idea - never even considered that. Cheers. Chris

BigFella1956

Thanks Eric. I'll check out the Zenith bolts as some reinforcement is required. Chris

BigFella1956

Thanks Mike T! I like the idea of a steel plate would help significantly with the reinforcement I need. Chris

BigFella1956

Thanks TedBear. Yes, the door was held on only by the spread of the rivets and it's now bleeding obvious I need to reinforce the area. Chris

MikeTNZ

Hi @BigFella1956,

May I just say this, thank you for very descriptive photo's in your original post,

we can't stress this enough, if people are looking for help, we need to see what has happened and how

we could possibly suggest some sort of a solution, your photo's were straight to the point!

Thanks,

Mike T.

BigFella1956

G’day Mike T, thanks for the feedback and you’re welcome. People like me who are jacks and Jill’s of all trades but masters of none are very fortunate to have access to people like you but we can’t expect you to be mind readers can we!? Hence the photos. I very much appreciate the quick responses from yourself and others. To close the loop on the shed door, there was not enough room between the door and frame to use screws of any kind so I used 150mm t hinges secured on both sides with security bolts through the metal and some merbau to strengthen the whole shibang and I put a chain on the door (thanks Dave). All the best mate, Chris

Jason

Great, thanks for letting us know @BigFella1956.

Feel free to post whenever you need a hand or have a project to share with other members.

Jason

jessle79

Hi Chris, I just stumbled upon this post, how did you end up fixing the hinge? I am facing the same issue after having already replaced the hinge with new rivets they failed and the doors fell off again really quickly. I bought stronger hinges and bigger rivets but they aren’t big enough and even the ones I used were too thick it makes the door not hang flush. I doubt my new fix will last long. 😂 so I’m keen to hear if your ideas worked!

JacobZ

Hi @jessle79,

Thank you for your question and welcome to the Bunnings Workshop community, it's fantastic to have you with us.

Please allow me to tag @BigFella1956 so they are notified of your question.

To add a possible solution to the problem, I would suggest moving the hinges up or down by around 100-150mm so they are no longer near the old holes. It is likely you are having issues because the metal where the old holes are is quite deformed. Moving the hinges to fresh metal will give them a much better surface to attach to.

Let me know if you have any further questions, I'd be happy to assist further if required.

Jacob

jessle79

Hi Jacob, thank you so much for your reply! 🙏 I’m not sure how to allow a tag? Sorry I’m only new 😂 or have you already tagged him and I don’t need to do anything? 🫣

Thanks for your suggestions, some of the holes were new on the other hinge but I couldn’t move the second one because the drill bits all snapped no matter how gentle I was (unfortunately they were brand new too) 😩

Can you recommend a better set than this for aluminium?

https://www.bunnings.com.au/ryobi-19-piece-metric-high-speed-steel-drill-bit-set_p0056805?store=7385&gad_source=1&gbraid=0AAAAADtbEB_fdMY2LooZ_9j1FC3eyjqkd&gclid=CjwKCAjw8fu1BhBsEiwAwDrsjKsTn6asMEBUucKlSaSlB-Q1y2yo5rem5tg5P9tidKyK1iHHpAQbyxoCQuEQAvD_BwE&gclsrc=aw.ds

thanks, Jess

JacobZ

Hi @jessle79,

Not a worry, I have tagged them, so they have been notified.

If you'd like to do so in future, simply put an @ followed by their username.

The best drill bits I've found for drilling metal are cobalt tipped, but they are fairly pricy. The Sutton Viper drill bits are also a good option.

Aluminium is a fairly soft metal, so any drill bits should work, but trust me when I say I have snapped my fair share in my time. It usually happens when you punch through and hit a second layer of metal. As the drill is spinning, it becomes accustomed to the torsional forces applied to it, when it suddenly hits a new surface, the different level of torque snaps the drill bit.

Start slowly with a small drill bit to punch through, then move up to the bigger drill bit in the size you are looking to drill. Start slowly and apply consistent pressure, you will start to feel when the metal is about to give way. When you feel it start to give way, ease off on the trigger and lessen the pressure, this will hopefully stop any further snapped drill bits.

Let me know if you have any further questions.

Jacob

Noyade

Good evening @jessle79

I could be wrong, but is the door on the left?

I had some long-winded suggestions - but thinking about this over a glass of wine (or two) I believe I would go to Bunnings and buy a length of 20mm gal square and cut to length to the height of your shed.

Drill out all those rivets seen on the right.

Insert the tube and bolt into place - something like this...

Maybe top/bottom/middle positions.

This then provides a new metal canvas to screw, rivet or whatever, but in the reverse direction - into the tube.

I hope you sort out your drilling issues.

I agree with @JacobZ - cobalt! 😁

Cheers.

jessle79

Thanks heaps @Noyade

That would seem like a really solid fix, I just don’t know if I can drill through the steel square tube as I’m already failing dismally trying to get through the thin aluminium and I only have a cheap household type battery drill 😖 thanks for the suggestion for the cobalt tip drill bits, I’ll get some when I go to Bunnings next ✅✅

I hope you’re enjoying your wine! ☺️

Dave-1

Good Evening @jessle79

Just to add to "snapping drill bits" 🙂 Yeah Ive snapped a fair few. Generally when I am tired and not paying attention and/or it leads into me forcing the drill and not drilling straight. The drill bit is hardend steel and has very little flex, So me pushing off center with the drill and trying to "force" the drill bit to do my bidding and "SNAP" its gone.

@JacobZ 's instructions on drilling are spot on, Ive used cheap drill bits and generally dont have any issue with them. They may blunt faster is all.

Dave

jessle79

@Dave-1 @Noyade

just going back to the snapping drill bits issue. One thing I am struggling with is the tip moving out of position before it grabs hold. My holes end up all over the place. If I put to much pressure to hold it in place the bit snaps.

Should I maybe be trying to clamp the hinge in place and use that as a guide somehow? Drilling into the aluminium accurately seems to just be taking so long and I’m no good at it.

I have a lot less issues with accuracy when drilling into wood because it grabs easily! Thanks again for your help guys ☺️

Jess

Noyade

Good morning Jess @jessle79

Just some Sunday porridge thoughts.

Try a centre punch (seen below) to make a 'divot' for the drill tip.

Shorter drill bits. This Trojan riveter set came with the various sizes of bits for the most common rivets. Note the difference in length to the long cobalt - less likely to snap.

Some members in the past have recommended "step" drills for sheet metal - seen below looking like Christmas trees.

Your shed is mild steel sheeting - not aluminium - tougher than you think. 😐

Noyade

But if you don't want to drill anymore - can we reuse what holes you've already made?

What size drill and rivets are you using?

Good suggestion from @TedBear on the previous page. Incorporating small washers with yours rivets.

The theory is you have an oversized hole for the rivet...maybe what you're experiencing now?

Riveting from the hinge side into an oversized hole...

A washer or too - and squeeze...

Not easy and you'd need someone to help as this will be on the other side of where you're standing.

It also looks like you have room for small round headed bolts based on the frame?

Would that be easier for you?

Cheers - and keep us posted. 😁

jessle79

Ah thanks @Noyade I will add a punch to my list, I think this would solve a lot of my frustrations! Kinda glad to hear it’s not aluminium, makes me feel less useless 😂 enjoy your porridge.

jessle79

Thank you 🙏 I actually used some washers yesterday! It was pretty hit and miss 😂 the original holes don’t look too bad really. I’m about to try and hang the second door. Hopefully it won’t take 4 hours like yesterday 🤞😂

JacobZ

Good luck @jessle79,

Keep us in the loop if you run into any issues and don't forget to share your results.

I'm sure with your newly added experience, you will make light work of the second door.

Jacob

Dave-1

Evening @jessle79

A center punch nails it 🙂 and please let us know how it goes 🙂

Dave

jessle79

@JacobZ well it looks like my skills need some more improvement 😂 I did get the second door hung but it won’t swing as it’s hanging too close to the bottom, I did chock it up when I was re-hanging it but the slab isn’t flat so it ended up not being up high enough. I’m going to have to take both doors off and start again. Such a simple fix and yet it’s now going to end up taking the best of 3 weekends. 🤦‍♀️ frustrating because I’ll be buying a new shed soon but I figure it’s a good opportunity to learn more about working with steel which I’m obviously uncomfortable with 😂

I tried using both the screws and rivets. One side of the hinge could use the bolts for and then just got lazy and went back to the rivets. I must say the bolts are going to be a lot easier to remove now that I need to take the door off again!

here’s some pics of what it looked like

jessle79

Thanks @Dave-1 I’m going to buy one this week

Dave-1

Morning @jessle79

Just to let you know, I still have hassels with rivets lol Practice is what makes it easy and believe me the three weeks wont be wasted. You will always have the knowledge you have learnt! 🙂 Then people will hit you up for your knowledge level! 🙂

Dave

Noyade

Nicely done @jessle79 ! 👍

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