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[Bobkelso]

Hi, one time I had same problem on my 33

(the original holes in the door side for the locking mechanism bolts had 2-3 mm cracks
and the allen bolts with conical head where pulled through a pair of millimetes into the door,
so the whole locking mechanism was not well fixed and I couln'd open the door
from inside the car with the lever in the panel, because the lever hadn't enought travel to make it work..)

I tried to fix it with 3 washers around the 3 allen key bolts as you said,
and door cannot close because of the allen key bolt heads that where
to much outside and where interfering with the door pillar catch.

So I used 3 washers only 1/1,5mm thick and with the hole diameter bigger,
then I turned the allen key bolts so strong that the washers became
conical shaped and allen key bolts could go some more mm inside the door
and door was perfectly working and very strong assembly,
no need for welding and you cannot see that it was a fixing ,
cracks are no more visible and the visible part of the 'conical' nichel plate
washers around the allen key bolt heads looks like an original part

[BigAl]

yup you got it guys
I can see where it has jammed, I will suggestit to the guys and see what we can make , thats after trying the jacking up the car trick
I should have tightened the allen bolts tighter i guess and never got round to it.
_________________
x2 33 16v
pictures http://www.alfa-pages.co.uk/viewtopic.php?t=5203

[BigAl]

The guys at the garage got the door open after taking off the door card and hammering away at the lock which had rusted solid.
Big thanks to alex for supplying a new catch lock.
_________________
x2 33 16v
pictures http://www.alfa-pages.co.uk/viewtopic.php?t=5203