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What do I do about worn door hinges on my '53 Cavalier? Here's a little video. I don't see anything in the service manual regarding worn hinges, and I'm assuming they don't have bushings I can replace as I don't see anything in the parts book.

NOS?
Check the boneyard?
Replace pin?
Take them to my machinist?

I haven't checked my parts car yet, I'll do that tomorrow, but I can't imagine they'll be any better.

I'm not sure they expected the cars to last so long as to wear out the hinges but if there is anything about them, it would be in the Service Counselors. That said, if something can be made once it can be made again but in the case of hinges, I'm not sure if it's practical or even possible to rebuild so probably best to replace. I have hinges still on doors (except for Henney rear side door hinges which are off and on the shelf) but better to go to one of the dealers for a quicker replacement.

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In theory you could ream the pin hole slightly larger and turn some new pins to match. That's pretty much my only idea.

I have spare hinges but in unknown condition.

Get some average and peak diameter, length, knurl and head area measurements off the old pins and hinge holes...realize that these are likely (best case) nominal or worn (slight undersize)...go hunting the various automotive suppliers (Bob Drake, Auto Parts Haven) and check ones that look similar. I found the front upper hinge pin (the concealed one) from my 37 senior is very close to and the length can be cut down from a 68-79 camaro hinge pin (I just leave out camaro bushings and use just the pin)...I may have to knurl the shaft to get an extra 0.001-0.003" diameter. Surprisingly, there are a lot of hinge pin kits available on the Internet, just actual dimensions on those parts are lacking, but you will find someone who lists dimensions eventually.

or,

Do what pgh ULTRA suggests. Unless you're a machinist yourself, expect to pay a journeyman machinist $60-140/hr (this is the lower end of rates)...my guess is about an hour per pin plus 2 hours measuring/setup...reaming the holes in the old hinges is ~1/2 hr each.

Only other solution is to ask the post-war guys (Joel Ray, Bob Stoltzfus, Gerry (SW Packards)) if they have a good/NOS set.

I would start with a cup of coffee and some internet searching after measuring the dimensions.

It depends on the pin size and how much material you have. It may be that you can ream up to a convenient metric size then install a metric bolt. For example, 3/16" reams up to 5mm then you can perhaps install a shoulder bolt for a hinge pin.

mcmaster.com/products/screws/thread-size~m5/shoulder-screws-2~/metric-alloy-steel-shoulder-screws/

Here's the deal. 56 400. Pin dia is .341 and the hole is .352 as measured. Pin 2.481 lg. and 2.362 up to the taper. Both not including head.

The support is 2.294 length of pin to clear both holes. Door side working length 1.686.

Half inch OD on the body side, .180 extra radius on the door side.

Body side is slight interference fit to pin.

Why not buy a pack of these, you can install them just with a drill press and the appropriate size bits.

kimballmidwest.com/10038

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