Door hinge rebuild kit

[Curt Chambers]

Hi. I just received a door hinge rebuild kit from Classic Industries for my 73 Charger. There are no instructions included with this kit. I already have my old hinges disassemble so I've got a good idea on how it goes back together. But I do have a couple questions for anyone who has installed one of these kits.

1. What size drill do I need to enlarge the holes to accept the bushings?
2. The upper hinge pins in the kit are much longer than the OEM ones. Do I simply cut off the excess, or just leave it there. The hinge would still work but it would look funny.
3. The factory pins were press fit and had a flattened portion on the end. Am I supposed to stake these replacement pins, or is the press fit good enough to hold them?

Thanks

Curt

 

[PurpleBeeper]

I don't know your specific answers, but I have rebuilt several sets of hinges....so all of this is "in general"
1. Measure the outside diameter of the bushing with some vernier calipers (maybe use some for free at Autozone, etc) & drill the hole to that size...."maybe" .001"-.003" smaller. Using a drill press makes the holes straight + you have much less "wobble" & the resulting holes are more true. If you screw up, you could always use a tiny bit of of JB weld to hold the bushings in if the hole gets a little oblong.
2. Your choice.
3. I've never staked my hinge pins, but I've always dropped them in from the top so gravity kept them in place (for the most part). I suppose you could stake them in if you wanted to.

 

[727]

Make sure to drill as true to the old hole as possible. It’s easy to get off if the hole is oval/oblong. If you get off center then you may have to enlarge the holes that bolt to the body or door to get proper alignment.

 

[Curt Chambers]

Thanks for the replies.

I mic'd the bushing and the OD is .418. The closest undersize drill bit I have is 13/32, which mic'd at .398. So I guess I'll go online and look for a .417" drill bit.

 

[Curt Chambers]

Can't find any drill bits to match that size. But I found a .417" reamer. Can I drill the hole with the 13/32 bit and then ream it to size?

 

[Dibbons]

I mic'd the bushing and the OD is .418. The closest undersize drill bit I have is 13/32, which mic'd at .398. So I guess I'll go online and look for a .417" drill bit.

I special ordered a "Z" drill bit at ACE hardware that measures .413" (like the old Mopar big block!). I pressed the bushings in carefully using a nut, bolt, and small socket.