Spent most of the day rebuilding the door hinges. We discovered that one of the old hinge pins was case hardened and it ruined the blade on a power hack saw, not a recip saw, one with a band. We finally wound up drilling the pin out with an end mill on a vertical mill. Only one of the four pins gave us any trouble getting it out. We wound up using a 20-ton hydraulic press and a torch. The other pins came out easily with a ball peen hammer and drift punch. We drilled the hinges for the new pins on the mill. They went together without a hitch.

TIP: If your pins are seized up in the hinge, use a lot of heat on the hinge to loosen the grip. The one we had trouble with was really frozen.

TIP: While the hinges are apart use a wire to clean the gunk out of the oil holes in the hinges.

Once the hinges were rebuilt, we mounted the passenger door and the fit was surprisingly good. Problem areas are pointed out in the photos in this Gallery.