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    Thread: DIY: MK4 Broken Glove Box Door Repair And Modification! Pics Inside!

    1. Member vasillalov's Avatar
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      12-25-2005 05:25 PM #1
      Hi folks,
      About a week ago one of my co-workers broke my glove box door while she was attempting to get her wallet/purse out of my glovebox. Of course, she knew nothing about using finesse when opening and closing the glove box door, and naturally it snapped!
      I thought: GREAT! What a wonderful Christmas present!
      Today I had a chance to look around the glove box and actually I fixed everything very easily. I did some modifications on the glove box to avoid future damage.
      DISCLAIMER:
      I am not responsible for any damage inflicted to you, your vehicle, your pet or your signifficant other by using this DIY. It comes with no warranty or guarantee for sucess. It is provided to you free of charge and you are welcome to modify it as much as you like for your own purposes. Use it as a pictorial guide only!
      PARTS AND TOOLS NEEDED:
      1. Various screwdriver bits: torx, flat head and phillips.
      2. Superglue (I used the Walmart brand)
      3. A small drill or utility knife
      4. Couple of drops of clean engine oil or other liquid lubricant

      STEP 1: DISASSEMBLY:
      Notes: First off, let me shed some light on the glove box assembly. The globe box door is held with two hinged to the glove box cage. Also, there are two arms that restrict how much you can open the glove box door. Finally, there is a pneumatic shock on the right side of the glove box which connects the glove box door with the actual glove box compartment. The purpose of this pneumatic shock is to slow down the movement of the door instead of just letting it slam open.
      The problem however is that this pneumatic shock is too stiff, especially when it is cold. It is because the shock is too stiff COMBINED WITH USER IMPATIENCE, that the the door hindes break so often.
      Here, I am offering a cheap, easy repair of the broken hinge AND a modification of the shock so that the chance of it breaking again is minimal.
      1. Start by carefully opening the glove box and emptying the contents.
      2. With the door open, carefully pry off the side dash panel:


      3. Here is how my glove box broke:

      4. From the side of the dash, look inside and close to where the glovebox door attaches to the dash. You should see something like this:

      5. Remove this round plastic pint. This pin is part of the hinge machanism.
      6. Here is how the shock looks like:

      7. Here is where the shock mounts to the glove box:

      8. Your goal is to remove the shock along with the broken hinge part out of the glove box. You can see that the shock twists in the shock mount as you open and close the glove box door.
      9. Using a torx bit, disassemble the shock mount from the broken hinge piece:

      10. Next, remove the hinge connector from the top of the shock:


      STEP 2: SHOCK MODIFICATIONS:
      1. Pry off the white plastic cap from the shock. Be carefull as it is spring loaded and things will fly off.
      2. Here is how the shock looks like from the inside:

      Basically, you have a piston in a closed cylinder and a return spring.
      3. Cut some of the spring coils out:

      4. Drill a small hole at the back of the shock body:

      5. Finally, put about 2-3 drops of clean engine oil or other heat resisting lubricant of your choice inside the shock body. I did not want to use regular grease because the grease also stiffens when cold. Engine oil seemed the right choice.
      6. Assemble the shock back. You will notice how much easier it is for the piston to move back and forth. Yet, it still provides some cusioning for the glove box door.
      Notes:
      *Cutting some of the spring coils will allow for shorter path of piston under tension
      *Drilling a hole at the back of the shock will allow air to exit faster and thus you will be able to close the glove box faster without putting too much tension on the hinges
      *The oil allows for faster piston movement.
      STEP 3: FIXING THE BROKEN PIECES:
      1. Using superglue, glue the broken piece of the hinge back to the glove box door:


      2. Make sure you line things up correctly so that there is no tension on the hinge.
      3. Allow it to dry for couple of hours or overnight.
      STEP 4: INSTALLING THE SHOCK MECHANISM:
      1. Once you have the hinge glued back together, put the hinge pin in to hold the door in place and travel its normal path.
      2. Next, attache the shock back to the shock mount:

      3. Close the glove box. This is crucial! You will see how the shock-to-hinge pin mount will line up with the front of the shock. This is the easiest way to do it
      4. Finally, slide the pin that connects the shock with the hinge mount.
      5. Carefully test the operation of the glove box. You will be pleased with the improvement!
      SUMMARY:
      It was easy: I did not have to disassemble the glove box or the dash.
      It was dirt cheap: paid only $1.06 for the superglue!
      It was fast: 2 hours of working 12 hours of waiting for the glue to harden completely
      IT WORKS!
      Good luck!



      Modified by vasillalov at 5:30 PM 12-25-2005
      Quote Originally Posted by MAG58 View Post
      Please consider your audience before saying something sensible. 80% of TCL drivers were actually banned from Formula 1 for being too fast.
      A turbocharger is a device in where exhaust gases go in, witchcraft happens, and then you go faster.

    2. 12-25-2005 05:53 PM #2
      dang, you delivered on the promise of a DIY, you my friend are a man of your word.
      nice work

    3. 12-25-2005 05:55 PM #3
      gj [IMG]http://**********************/smile/emthup.gif[/IMG]

    4. Member dubchester's Avatar
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      12-25-2005 06:40 PM #4
      omg. thank you, same thing happend to me and it so annoying I have to slam it shut to get it to lock and not sag. your a life saver

    5. Member Martinus's Avatar
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      12-25-2005 07:07 PM #5
      Yeah, people break the glove box door ALL the time, ( the little shocks are too stiff, and the door opens too slow. so ) people just reef down on them, and break the catch/stopper.
      Happens ALL the time, so much so, that VW actually makes weaker little shocks. ( so the door opens faster. )
      If you don't belive me "look into it". [IMG]http://**********************/smile/emthup.gif[/IMG]
      BTW - finally proff, that "cutting springs, makes them stiffer".

    6. 12-25-2005 07:44 PM #6
      Good write up. I didn't have the patience nor the time to fix mine so I threw it in the garbage

    7. Member vasillalov's Avatar
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      12-26-2005 08:48 PM #7
      bump for those who missed it yesterday
      Quote Originally Posted by MAG58 View Post
      Please consider your audience before saying something sensible. 80% of TCL drivers were actually banned from Formula 1 for being too fast.
      A turbocharger is a device in where exhaust gases go in, witchcraft happens, and then you go faster.

    8. Member Andy35's Avatar
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      12-26-2005 09:07 PM #8
      Great DIY [IMG]http://**********************/smile/emthup.gif[/IMG]. You definitely deserve a .

    9. 12-26-2005 09:12 PM #9
      perfect, just what i needed, mine broke last week!

    10. 12-26-2005 09:16 PM #10
      Nice job on the DIY. [IMG]http://**********************/smile/emthup.gif[/IMG] I'm sure it will be helpful to numerous people

    11. Member Wells's Avatar
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      12-26-2005 10:08 PM #11
      AWESOME MINE JUST BROKE!!! so glad i found this Thanks alot man

    12. 12-26-2005 10:15 PM #12
      awesome! Cant wait to do this along with installing my new aluminumum trim in a few weeks. [IMG]http://**********************/smile/emthup.gif[/IMG] [IMG]http://**********************/smile/emthup.gif[/IMG]

    13. Member Ricky Bobby's Avatar
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      12-28-2005 05:48 PM #13
      i have some extra jb weld laying around, you think i could use it on the broken hinge and yield the same results? or should i go get some super glue?

      great DIY, i plan on using it soon [IMG]http://**********************/smile/emthup.gif[/IMG] [IMG]http://**********************/smile/emthup.gif[/IMG]
      Quote Originally Posted by Senor Pelligro
      It's a car for a fashion forward, style conscious guy that's always looking for the season's hottest accessory. A guy that watches Project Runway, reads TMZ, and drinks Cosmos.

      It's simply fabulous, sweetie.

    14. Member spkn^GRMN's Avatar
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      12-28-2005 05:58 PM #14
      [IMG]http://**********************/smile/emthup.gif[/IMG] nice work!!!
      -Wes

      2015

    15. Member vasillalov's Avatar
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      12-29-2005 09:00 AM #15
      Quote, originally posted by kurtanglevr6 »
      i have some extra jb weld laying around, you think i could use it on the broken hinge and yield the same results? or should i go get some super glue?


      Well I strongly recommend using superglue in the beginning to attach the broken hinge piece back to the door. The reason is because you have to hold the door in place while the superglue makes the innitial "connection". If you start moving back and forth, you WILL move things out of alignment.
      After the initial session of superglue, you could "cement" things with jbweld or whatever you want.
      Quote Originally Posted by MAG58 View Post
      Please consider your audience before saying something sensible. 80% of TCL drivers were actually banned from Formula 1 for being too fast.
      A turbocharger is a device in where exhaust gases go in, witchcraft happens, and then you go faster.

    16. Member Ricky Bobby's Avatar
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      12-29-2005 11:49 AM #16
      Quote, originally posted by vasillalov »

      Well I strongly recommend using superglue in the beginning to attach the broken hinge piece back to the door. The reason is because you have to hold the door in place while the superglue makes the innitial "connection". If you start moving back and forth, you WILL move things out of alignment.
      After the initial session of superglue, you could "cement" things with jbweld or whatever you want.


      awesome, thanks for putting this DIY together, saved my 45 bucks on a new glove box [IMG]http://**********************/smile/emthup.gif[/IMG] [IMG]http://**********************/smile/emthup.gif[/IMG]
      Quote Originally Posted by Senor Pelligro
      It's a car for a fashion forward, style conscious guy that's always looking for the season's hottest accessory. A guy that watches Project Runway, reads TMZ, and drinks Cosmos.

      It's simply fabulous, sweetie.

    17. 12-29-2005 12:18 PM #17
      thanx [IMG]http://**********************/smile/emthup.gif[/IMG]

    18. 12-31-2005 03:47 PM #18
      awesome, just did this last night, worked like a charm... although i dont know if I did a great glue job, we'll see how long it lasts.. Thanks a bunch man!

    19. Member murkywave's Avatar
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      01-04-2006 02:18 PM #19
      Thanks for such an easy-to-follow and detailed write up. I just did it, and am waiting for it to set. I used a plastic weld instead of superglue. It looks a bit messy, but I figured the hold would be a bit more permanent.
      Thanks again--this was the first Vortex DIY I felt confident enough to actually perform!

    20. Member Ricky Bobby's Avatar
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      01-08-2006 04:16 PM #20
      little super glue last night, little jb kwik weld today, i dont think that the glovebox will ever break again [IMG]http://**********************/smile/emthup.gif[/IMG]

      Thanks for a great DIY [IMG]http://**********************/smile/emthup.gif[/IMG] [IMG]http://**********************/smile/emthup.gif[/IMG]
      Quote Originally Posted by Senor Pelligro
      It's a car for a fashion forward, style conscious guy that's always looking for the season's hottest accessory. A guy that watches Project Runway, reads TMZ, and drinks Cosmos.

      It's simply fabulous, sweetie.

    21. 01-08-2006 05:14 PM #21
      excellent diy!!! will do this weekend!

    22. Member petch's Avatar
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      01-08-2006 10:56 PM #22
      mine just broke the other day. looks like i have another diy to add to the list. looks like a great write up though [IMG]http://**********************/smile/emthup.gif[/IMG]

    23. 01-08-2006 11:02 PM #23
      I was doing this earlier today but it started to rain. Damn my tiny garage and my GTI's huge doors

      How did you removee this pin? I wasn't using any tools and the rain started pouring, so I never got a chance to really try things out
      And can you do this if your hinge isn't broken?

    24. Member vasillalov's Avatar
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      01-08-2006 11:03 PM #24
      Quote, originally posted by bootymac »
      I was doing this earlier today but it started to rain. Damn my tiny garage and my GTI's huge doors

      How did you removee this pin? I wasn't using any tools and the rain started pouring, so I never got a chance to really try things out
      And can you do this if your hinge isn't broken?

      Yes, you can remove it when the hinge is NOT broken.
      Use a stubby screwdriver to pull the pin out.
      Quote Originally Posted by MAG58 View Post
      Please consider your audience before saying something sensible. 80% of TCL drivers were actually banned from Formula 1 for being too fast.
      A turbocharger is a device in where exhaust gases go in, witchcraft happens, and then you go faster.

    25. Member Martinus's Avatar
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      01-09-2006 05:42 PM #25
      OK, What the hell is a globe box ? there is no way you're getting a regular size globe in there.
      Seriously, just buy the new shock ( 50$ ) and glove box door. ( 100$ ) You know, you will just be repeating ALL the steps in a week... because we all know glueing/jb welding stuff back together lasts forever.

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