I did not remove the hinges from the lid, I just removed the two screws either side of the chesty that secured the hinges to the body of the freezer. I left the plastic caps on the spring ends and then secured the lid back down with the same two screws on either side of the collar (one of the screws at each side actually goes into the top of the freezer itself.
The trick I found, after having similar frustration when trying to brute force it, was to do the following:
Hey presto... working hinged lid. I am absolutely convinced that it is impossible to get those torsion bars in any other way... not that I didn't try pretty hard first.
- Screw the bottom half of the hinge to the collar. You'll notice it has a little hook sticking up to hold the torsion bar in place.
- Line up the lid in a fully open position at the back of the freezer (flipped right the way back so it is 180 degrees open... you'll need some room for this maneuver). Probably easier to get someone to hold it in this spot but I did it solo by balancing the lid on two kegs with buckets on top.
- Once the lid is in this position the torsion bar can slipped behind the hooks on the bottom half of the hinge that is screwed to the collar. With the lid 180 degrees open there is bugger all tension on them.
- Then fit the little plastic shoe over the end of the torsion bar to prevent it digging in to your collar. Now the torsion bars are in place with the shoes, my collar is holding up fine to the pressure.
- Then slowly fold the lid up towards 90 degrees open until you can line up the top of the hinge enough to bang in a few screws.
I've got the lid on the collar, and have the hinges all sorted.
The plastic bits are not strictly needed I suspect, but they help keep the wires from getting loose or gouging the wood etc. If you loose them I'm sure something else could be done.
The two hinge wires need to bent around forward horizontal facing the front of the fridge, and they jsut sit along the top of the collar.
I was convinved I'd need two other strong sets of hands and pliers to get it sorted, and after fighting with it for ages I found that patience and a deft touch slowly worked the springs into place first and then lowered the lid down flush against the collar, and hey presto screw it in place. I did it all without any help whatsoever, and my collar isn't 100% square in all direction, and is only 19mm thick, so its far from perfect for this setup.
If you are gentle and patient you'll get it.