I posted this in another thread I started but its kinda buried so here ya go.

Items to have handy:
1. Door Hinge repair kit w/ bushings. Get a PIN style kit with bushings. (I'll see if I can find my part number)
2. Buy 2 packs of the assorted hinge bushings. You'll need them for test fitting and for F-Ups.
3. Cutting tool for tight places (Air hammer, Torch, Sharks Teeth.... Whatever you can get to cut metal) If you use your old man's wood chisels, he will prolly break your face… Not advised
4. MIG/TIG Welder OR if you can Braze w/ a torch, that should work also. If you trust JB Weld, you can prolly use that also.
5. Gloves, your BFF, a BFH (Big F-in Hammer), and a punch set
6. Something to get drunk with when you get pissed!
7. Buy 2 to 4, 3/8"x 6" Galvanized Nipples; Mine had threads on both ends but they get cut down so don’t spaz yet... FITMENT NOTE: Take those assorted bushings you bought and take out some of the larger OD bushings. Look at the metal pipe you have in your hand. Now, fine the pieces that have a firm fit, DO NOT BEAT THEM IN... If you do, you’re not a cool person and you'll prolly have to use another bushing. A "love tap" with your BFH should suffice.
8. Drill and 3/8” drill bit
9. Vise

Step 1: Remove the door panels and disconnect any wiring. You don’t have to remove the wiring completely from the door if you have a table or something to rest the door on.

Step 2: Unbolt the hinges and lay the door down on a table or where ever you are going to work.

Step 3: Remove the rivets from the top hinge. I used an air hammer but if you can get a torch in there, go for it. You’re gonna have a hell of a time w/ a sawzall but a small grinder MIGHT work. NOTE: make sure to LOOK at the hinge and cut the SMALL side of the rivet... If you dont do this, your just doubling your work.


LOOK AT PICS FROM HERE ON OUT!!


*** At this point you should have 2 pieces to work with. The piece on the door and the piece that went on the body. Were going to deal with the piece that goes on the DOOR first. ***

Step 4: With the door on its side, put one of the pieces of the piping through the holes of the hinge, then, mark the pipe on the OUTSIDE around the holes. Now put the pipe in a vise or on a chop saw and cut the marks. You might have to shave them down a few times to get them in the right place. FITMENT NOTE: The ends of the pipe should be about ½ way between the top of the hole and bottom of the hole on both sides so your bushings will mate up on both hinge parts. Once they are cut to the correct length, Weld them into place.

PIC 1&2

Step 5: Go grab your drill, 3/8 drill bit and the body side of the hinge. You are going to have to wallow out the holes to take some of the bushings. (In my pack of bushings there were some that had thin brass and there were some that were just a bit bigger, those are the ones that I used for the body side hinge.) This process will take a while but don’t get too pissed off… It took me about 45 min to drill mine out because I test fitted about every 2 “rounds”; Over-kill… yes… Exact fit, YES.

Step 6: Once you have all of the bushings on the body side hinge, just put it back together and put it on the car.

PIC 3

*** If you need to do your bottom hinges, just a regular hinge repair kit for GM cars should work. I did not have to do mine.***

 

I may have tried to custom make a hinge kit (and was going to due to price of kits) but yesterday I found them on e-vil-bay for $58 for stainless steel version. My car budget is getting slim but I only needed driver side. Still, $58? Why would GM design that crap? If GM would have designed it so that the two wear surfaces were from top to bottom and not concentrated on two spots little more than 1/8 wide it would last.

 

i read on ANDYZ28 site, that kit works also on 4th gen, so, on ebay there are a set of four upper pins for $73 im wondering if it work on thirdgen also

 

If it is the ones I'm thinking about, I asked if those 4 pins worked on a 3rd gen and got no reply.

I originally went to Top Down Soln but the web site said he was out of pins. So I searched ebay and found
Seller:Member id totalauto ( Feedback Score Of 2822)
Contact seller

 

ATCFLY,
That looks like a pretty good idea I might try that soon. BTW in Birmingham, do they still love the governa? PLAY SOME SKYNARD!!!