My Door Hinge Repair - Welding and boring the door side hinge

[mhinchliffe]

Ok - I had finally a few spare moments to go out to the shop to study and formulate a repair for my 49 year old sloppy door hinges. The following is what I did.
Removed the passenger side top hinge (the worst one)
Pressed pin out in 20 Ton shop press
Finished removing pin with drift pin
Marked each half for reference so I didn't mix things up
Brass wire wheeled the pin
Media blasted hinge pin hole in door side hinge
Measured the pin diameter - 0.281"

Measured the hole I.D. of the A pillar hinge - 0.2815" and 0.2805"

Measured the hole I.D. of the door side hinge - 0.297" and 0.2965"

Filled the I.D. of the door side hinge with weld top and bottom

Located the center
Drilled a pilot hole utilizing mill

Drilled on size hole for pin - 9/32 or 0.28125"
Aligned match marks

Installed pin into hinge

Reinstalled hinge into door and pillar
Now working through realigning door to body

 

[DirtDonk]

Great writeup and details and pics. Thanks!
Can't wait to hear the final report, but it sounds good so far.

Any way to insert a grease fitting into one side to make keeping lubed easier?

Paul

 

[hunter1]

Door hinge

I done this last year on mine. I was able to use a hammer to break the pin loose from the hinge and a drift to drive it out. All of this was done with the hinges off and driving against the edge of the vise. I then used a 5/16” drill to open up the holes in both hinge pieces. It drills easy with a sharp bit. I then used 5/16” drill rod, .3125 to make the pins. I tapered the bottom and again drove them in against the vise for support. Came out super tight with zero play.

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[mhinchliffe]

That's nice work right there Hunter1.