Hinge arm repair

1. A method for repairing a hinge arm having a hinge pin hole having a worn bore, the method comprising the steps of:

forming in the worn hinge arm a new hole with a keyway extending outwardly from the new hole; and

providing a keyed bushing having a cylindrical body and a key extending outwardly from the cylindrical body;

drilling a central bore extending axially through the keyed bushing; and

inserting the keyed bushing into the new hole and keyway formed in the hinge arm.

2. The method for repairing a hinge arm as recited in claim 1 wherein the step of forming in the worn hinge arm a new hole with a keyway extending outwardly from the new hole comprises the steps of:

drilling the new hole coaxially through the worn hinge hole, the new hole having a larger diameter bore relative to the worn hinge pin hole; and

machining the keyway in the hinge arm, the keyway extending outwardly from the new hole away from a strap portion of the hinge arm.

3. The method for repairing a hinge arm as recited in claim 1 wherein the key and the keyway are sized relative to each other to provide a press-fit between the key and the keyway when the key is inserted into the keyway.

4. The method for repairing a hinge arm as recited in claim 1 wherein the keyed bushing has an outer diameter and the new hole formed in the hinge arm has a bore diameter, the outer diameter of the keyed bushing and the bore diameter of the new hole sized relative to each other to provide a press fit between the keyed bushing and the bore of the new hole when the keyed bushing is inserted into the new hole in the hinge arm.

5. The method for repairing a hinge arm as recited in claim 1 further comprising the steps of:

providing a staking hole extending transversely into the hinge arm through the keyway and the key of the keyed bushing disposed in the keyway; and

inserting a staking pin into the staking hole, the staking pin extending transversely through the keyway and the key of the keyed bushing disposed within the keyway.

6. The method for repairing a hinge arm as recited in claim 5 further comprising the step of sizing a shaft of the staking pin relative to the staking hole to provide a press fit between the staking pin and the staking hole when the staking pin is inserted into the staking hole.

7. The method for repairing a hinge arm as recited in claim 5 wherein the step of inserting a staking pin into the staking hole comprises threading a threaded staking pin into the stacking hole.

8. The method for repairing a hinge arm as recited in claim 5 further comprising the step of locking the staking pin in the staking hole with a retaining compound.

9. A method for repairing a hinge arm of a hinge assembly of an access door on a gas turbine engine, the hinge arm having a hinge pin hole having a worn bore, the method comprising the steps of:

drilling a new hole in the hinge arm coaxially through the worn hinge hole;

machining a keyway in the hinge arm, the keyway extending outwardly from the bore of the new hole away from a strap portion of the hinge arm;

providing a keyed bushing having a cylindrical body having an outer diameter and a key extending outwardly from the cylindrical body;

sizing the outer diameter of the keyed bushing and the bore diameter of the new hole relative to each other to provide a press fit between the keyed bushing and the bore of the new hole when the keyed bushing is inserted into the new hole in the hinge arm;

sizing the key and the keyway relative to each other to provide a press-fit between the key and the keyway when the key is inserted into the keyway;

drilling a central bore extending axially through the keyed bushing; and

inserting the keyed bushing into the new hole and keyway fanned in the hinge arm.

10. The method of repairing a hinge arm as recited in claim 9 , further comprising the steps of:

providing a staking hole extending transversely into the hinge arm through the keyway and the key of the keyed bushing disposed in the keyway; and

inserting a staking pin into the staking hole, the staking pin extending transversely through the keyway and the key of the keyed bushing disposed within the keyway.

11. The method for repairing a hinge arm as recited in claim 10 further comprising the step of sizing the staking pin relative to the staking hole to provide a press fit between the staking pin and the staking hole when the staking pin is inserted into the staking hole.

12. The method for repairing a hinge arm as recited in claim 10 wherein the step of inserting a staking pin into the staking hole comprises threading a threaded staking pin into the stacking hole.

13. The method for repairing a hinge arm as recited in claim 10 further comprising the step of locking the staking pin in the staking hole with a retaining compound.

14. A repaired hinge arm for a hinge assembly for an access door of a gas turbine engine, comprising;

a hole extending through a distal end of the hinge arm, the hole having a keyway extending outwardly from hole into the hinge arm; and

a keyed bushing disposed within the hole through the hinge arm, the keyed bushing having a cylindrical body having an outer diameter, a central bore extending axially therethrough and a key extending outwardly from the cylindrical bore into the keyway, the key of the keyed bushing being staked to the keyway.

15. The repaired hinge arm as recited in claim 14 wherein the keyed bushing has an outer diameter and said hole formed in the distal arm of the hinge arm has a bore diameter, the outer diameter of the keyed bushing and the bore diameter of said hole sized relative to each other to provide a press fit between the keyed bushing and the bore of said hole when the keyed bushing is disposed within said hole.

16. The repaired hinge arm as recited in claim 14 wherein the key of the keyed bushing and the keyway in the hinge arm are sized relative to each other to provide a press-fit between the key and the keyway when the keyed bushing is disposed within said hole.

17. The repaired hinge arm as recited in claim 14 further comprising: a staking hole extending transversely into the hinge arm through the keyway and the key of the keyed bushing disposed in the keyway; and a staking pin disposed in the staking hole, the staking pin extending transversely through the keyway and the key of the keyed bushing disposed within the keyway.