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I have a 1991 Firebird Formula that has an awful saggy driver's door. This door is not original as my roommate and I swapped it out for another door from a 91'; the original had some issues and this one appeared in better working condition. When we first put the new door on it seemed to work well with very minimal sagging. A few days later it started to fall. We noticed the pins and bushings didn't look great so we took the door back off and replaced all of the pins and bushings. While doing so, we found that the lower pin hole on the bottom hinge appears stretched. The pin was swimming in it and wouldn't sit right, so we did a temporary fix and shimmed it. Shimming seemed to work well. Now we are at the point where the door is sagging horribly to where you have to lift it up and slam it to get it to close. We had someone look at it yesterday and he said the bottom hinge is warped. So not only is the hole stretched but the hinge itself is warped.
I am looking to get some suggestions on how to go about fixing this. I do know you can purchase new bolt-on hinges from Hawks, but the current hinges are welded on to the door. If I did go that route, would I replace just the lower hinge or should top and bottom be done simultaneously despite the top seeming to be ok? Is there any other method to fixing a stretched pin hole and warped hinge aside from replacement?
Lower Hinge
Upper Hinge
This is the gap between the fender and door. You can see the damage this has done.
If I recall correctly on mine I drilled it out to a larger size pin. They sell a multi size bushing kit at the parts store. I think I drilled mine out to a larger bushing then ran a Long 3/8 bolt through it with lock nut. I will take a pic when I get home today
the wallowed out lower pin hole can be 'fixed' by welding an appropriate sized nut onto it to center the hinge pin. might be worth a try before replacing the hinge.
Since you replaced the door im guessing that hinge side is good, so the body side is the one thats warped. That side bolts on, i would try just replacing that half of the hinge and leave the welded half alone.
