The new engine lid I bought for the van is for the later pin style hinge, and as I wanted to keep the earlier proper hinge I needed to convert the mounts.
The first step is to cut off the pin hinge and weld shut the hole:
Then cut the slots for the hinge:
I was originally going to fit rivnuts but I wanted adjustable nuts, and rivnuts would sit slightly proud of the surface so I had a cunning plan.
Firstly drill holes for where the nuts will sit, but additionally drill a secondary small hole next to it:
Then in an attempt to replicate a cage nut, fabricate a u shaped bracket with a tab to weld to which fits the nut with a small amount of wiggle room (I welded blobs to the corners of the nut too):
Then using a pair of allen keys coax the nut and bracket into position behind the holes and hold in place with a cleco clip (unbelievably faffy and very nearly resulted in me throwing the engine lid across the workshop):
Followed by a confident plug weld through the hole to hold it all in place.
Repeat on the other 3 nuts and the job is done. The lid fits pretty much perfectly now:
And shuts with a satisfying thunk:
