Anyone got any tips for removing the door hinge screws? They may as well be welded in place!

Torx bit did the trick for me!!

Yeh worked fine on my original car but the donor car snapped the torx bit lol.

Took me ages to do mine. Literally several days in a row of WD40ing it and trying to undo it.

But yet when we took that door off of Aaron's car to put on mine, both the bolts came undone fine. Just luck I suppose lol

Yes I was thinking about that earlier, you were very lucky! Kinda wish I'd got the back door but I don't know if it would have fit and I was shitting it a bit over my alt and tyre that day.

Yes they were pretty major distractions

While we're on the subject, what kind of grease would be best to use when fitting new hinge pins? Just your average all purpose grease?

That's what I used yes, but I'm sure there's some supa-dupa Peugeot-only grease you're supposed to buy or your doors will fall off in a week.

I found lithium based grease quite good in this application. It stays there quite well.

I tried getting a door pin out at the weekend. It started to round the bit so I stopped before I made it worse. Will have to get some WD40 on it and see if that helps.

Got all the doors I needed off the spares car now and all the other bolts came out with no fuss. Just a month of sundays and a handsaw on that one on the drivers side! (Took the front wing off the get better access) Agree with the Lithium Grease for lubin the hinges and door straps (these where clunking horribly before a good dose, not a peep since).

Impact drivers can be effective since the shock can break the rust/paint seal. Common sense applies, don't start hammering something unsupported or full of rust. They also work well by hand as a screwdriver since you can get a far better grip

Quite cheap to buy and get one with as many bits as possible, especially phillips and posi cross heads (they look similar but the profile is different and can mean a chewed up head or a loosened one). All come with a socket drive so you can put a torx socket on. Most outlets do them, as an example Machine Mart do a couple, one 15 piece set 1/2" drive @ £14.09, another 7 piece set 3/8" drive @ £7.04. Neither come with posi or torx so you would have to sort out the fitting you need.

Silverline do a set of 3/8" torx bits, T40, 45, 47, 50, 60 - not sure size you need, but make sure it is an exact fit. Socket drive bits also open up the whole range of extensions, adapters, ratchets and breaker bars.