One of the few major weak points in the design of this wonderfull machine is the lower hinge on the rear pocket doors. The previous owner of this old girl told me he got sick and tired of the doors falling off so he glued them in place with Silicone RTV sealant. Now if that was not bad enough both doors where right hand doors. After prying them free and cleaning the adhesive I had one servicable door.

The weak spot here is the molded plastic hinge pin, these snap off then your door is flopping in the breeze.

My repair method only requires a drill, a rat tail file, bolt cutters, a bit of welding rod or similar round stock, and a few tyraps (zip ties).

The first step is to use the rat tail file to carve out some concave reliefs where the original pin was. Only file enough material so that the new pin (your welding rod or 1/8" round stk) will sit right in the original pins axis.

Next drill 4 small holes equal in diameter to the width of your tyraps, the tyraps will pass through these holes and keep the pin lodged in the concave pocket you just made.

Go ahead and get your tyraps in place as shown.

Cinch up your tyraps and trim them off anf you will have a nice solid repair that should outlast the original design by a large margin. Here is a breif video clip of the repared door pocket in action.

Remember that if you are ordering replacement doors from Honda the door DOES NOT come with the latch/handle, the spring, or the screw. They are all still available as of Spring 2008 right from HiondaLine Direct.