Well I have new enthusiasm as a young local lad just starting out in the resto biz is interested in completing the rust repairs, prepping the shell and painting for what I think is an unbeatable price.
Now as I want to give him the doors, bonnet and bootlid to get started I want to sort out the worn hinges - particularly on the D/S door.
First issue is getting the 35yo roll pins out. Trusty hammer and pin punch with a few sprays of CRC worked wonders on the upper and it popped out with ease
Then I turned to the lower which had worked its way out the bottom and sitting hard against the inner door skin - what to do. I thought I could cut it off with a disc but I couldn't cut all the way through due to the confined area. And then I had a cunning plan
If I was to cut part way through the pin could bend and follow the natural curve along the inner door skin until it was able to come out - worked a charm!
As the hinges are worn I'm thinking of either just drilling oversize and using bolts or sleaving with a bronze bush and using a suitable sized nut and bolt - either way I'm not going with a roll pin again!
 

martymexico
Paul , may i suggest to use vn-vz commonbored door roll pins. .. They are 8mm dia and galvanized with a flare at one end. I've been using these for 10yrs on my restos and usually fix the wobbly door dramas...
Cheers Aye !

Thats a great tip Paul, thanks for that
 

I think escort pins are 7.6mm or what that comes at in imperial 9/32 ??
My van pins were rotted and oval holed but now good with them new pins in.
If you gotta drill go out to 9mm . better yet get the hinge mounts from a 4dr rear door set. .. Usually never used in the cars life so being as good as they come , i might have a set laying about. .

it's the middle part of the hinge that the pin bites to so the small end bits turn free.
Cheers mate I'd forgotten the X member lol.

How did you go when drilling it out? looks like you wouldn't have much room to play with the drill. No problems with angles?

Nice work! Turned out really well

Ok. Small update. Threw together my new front brake / strut configuration.
PS I know the caliper etc are on the wrong side!!
Gaz Golds bolt up beautifully with the HiSpec 260mm kit and the alloy hubs using the CBC F104 wheel bearing kit.
Only wish I had something as shiny to bolt them under 😡

Looking excellent Paul! Nice when it all finally bolts together.
Do you know if they are the short/tarmac GAZ struts? Or are they all just the same length?