Hello inventors, this is my first instructable. Hope that this proves helpful for some people like me, who broke their hp printer's door hinge and made it piece of plastic of no use.
This guides you how to fix a broken printer door hinge and make the door sensor work.
This is a very known bug in HP officejet printers. When you Open the door in order to change the cartridges or remove a jammed paper after a long time since the door was lifted, the hinges gets stuck and cracks. And that;s when you screwed it up.There are no repairs available with HP aswell. They'll charge your pockets on fire if you get the upper section replaced, no matter your product is under warranty or not.
So, if you have not yet cracked the door hinges, put some silicon oil or any other suitable lubricant between the hinges.
later we'll also fix a broken door sensor trigger, in this instructable.
OK, now we need the following things:

1. 3 Small size door hinges - refer image
2. Epoxy Putty
3. Industrial glue
4. Duck tape
5. Hexalobular star screw driver(maybe different headers for other models/printers
6. Screw bridge or any alternative similar shaped piece of plastic for the broken door sensor trigger

Here we go.......

Step 1: Unscrew and Remove the Broken Hinges

Unscrew all the screws and remove all the plastic covers and hinges as we dont need this mechanism anymore. The upper and lower part of hinges are clip attached.
you need a Hexalobular star screw header for HP printers.
There is a plastic cover where inside are the two screws of the upper section of the hinge , then two screws on the other side of the door.
Remove them all. Make sure you dont damage the wires connecting the upper section.
<p>Just busted this printer's hinges tonight..thought she was a goner! I'm so excited that I can fix it as I really need it, and REALLY can't afford to replace her right now. you ROCK!!!</p>
<p>Great item. Thought I was the only one with hinge problems! I attached my replacement hinge with a smear of 2-part epoxy on a brass hinge that was then pop-riveted to the top cover and chassis. Just make sure there is no epoxy on the hinge itself!</p>
<p>This is brilliant, I had everything I needed lying around the shop. The printer has proven to be a workhorse, reliable, easy to deal with. I would hate to throw it away for the little bit that went wrong.</p>
<p> just want to add some suggestions: after your done fixing this printer with the hinges. Put a short string on both sides of the cover, just measure the length of the string base on how far the top cover will open as not to damage the ribbon cable when you open it to change cartridge or do maintenance ex. paper jam</p>
<p>Awesome instructables...you just save me a lot of cash in a buying a new printer. Very helpful indeed, added it in my collection and favorited. Just one question can i used a screw on the hinges plus glue it. Is there any ribbon cable or wires that will get damage? LIFESAVER...YOU ROCK DUDE!</p>
<p>Life Saver! Thank you so much!</p>
<p>just what i needed</p>
<p>Yahoooeeee! I can't believe I found this on a whim Google search after I snapped my hinge on this exact printer! Sadly I have already beat on it, twisted it and what not and have exposed the flat white plastic cable cords?? to the scanner. Think all hope is lost?</p>
<p>I'd say probably not, guessing you've already tossed it but if you haven't there are just a couple of ribbon cables providing those aren't damaged you maybe able to salvage them.... give it a shot, you really have nothing to lose.</p>
<p>Thanks K - I actually did save it and have been using it without a hich. The cables were fine once I got them stuffed back in, it was just the hinge. Thanks again :-)</p>

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More by hansumkrishna:How to fix a broken printer hinge and door sensor (HP Officejet J6488 All-in-One - maybe helpful for other printers too) 
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