This guide will show how to correctly install the hinge extenders on the Delica L300. There are many ways to do this installation incorrectly. take your time and follow this guide to ensure smooth operation.
1. Remove the sliding door interior card by removing the handle and popping the panel clips with a panel popper tool. There is also one push-clip in the center of the panel.
2. Open the door and support it with a jack. Use a block of wood to prevent the jack from damaging the paint. Then remove the 2X 12mm bolts that mount the OE hinge to the door. Set aside the bolts as the will be used later.
3. Swing the door outward on the jack and remove the plastic end cap form the track.
4. Extract the OE hinge mechanism. Use a cut-off wheel to cut the pin and separate the two parts of the OE hinge. The sliding portion will be used for the extender. Be careful not to loose the two plastic bushings that sit on the slider. If these bushings are worn it is worth replacing the to ensure smooth sliding.
Recommended Upgrade: We replaced our worn bushings with 6x10x9 needle roller bearings. This made the slider lot smoother. You can buy them here: Roller Bearings
5. Cut the door as shown below. Drill holes in the corners of the cut for cleaner removal. Paint to prevent rust.
6. Bolt the hinge extender to the door in the most aft position using the supplied socket head bolts and lock washers.
7. Bolt the extender to the OE slider using the 2X 12mm bolts from Step 2 and the supplied nuts. The extender should NOT be pivoting at this joint. It is a fixed bolted joint. The angle at which the extender is mounted to the slider is critical for correct operation. Secure the extender at a 58 degree angle.
8. Close the door slowly and carefully to ensure no binding or interference. Then close the door at normal speed to ensure it fully latches. If you run into interference or binding, the position of the pivot point or extender angle may need to be adjusted. Take your time to find the sweet spot.
If the slider is binding in the track then lube the track and/or replace the slide bushings with the roller bearings.
9. Trim and install the included foam insert. This will help eliminate any draft/ wind noise. The supplied edge trim can also be applied. Applying a bit of heat can help the edge trim form to the corners.
10. Cut the door card to accommodate the extender:
11. Reinstall the door card to complete the installation.