I bought oversize hinge pins in an effort to reduce door sag and have had quite the problem removing the old ones, been there I guess since '67. Anyone have a new, innovative way to remove the old ones? VW had a special tool for the job but I only have a large hammer and penetrating oil.
I've been working on the top one in the passenger door of my '66 for an hour or two every couple of weeks for about 3 *MONTHS* now. I want to install a passenger side mirror. Door doesn't sag.
I'm trying REALLY hard to do it without a torch but I have seen exactly
0mm of movenemt in the pin using all manner of heavy instruments right up to going after it with an air hammer using a "pointy" tip.
After the last session I get the idea that there may be a bit of extra binding on that top pin from the door weight even though I've tried blocking the door up and working on it with the door firmly closed.
I guess the next step will be to remove the door and use a torch to heat it up.
I find it hard to believe myself but when I had the same problem with my son's '62 a couple of years back, I ended up not only having to heat one of the hinges to cherry red, but also had to use an air chisel to get the sucker out!
I modifed a spade-shaped chisel to provide some offset to clear the door panel (imagine a lower case 'j' with a little less offset on the tail.) Even with all this heavy artillery to work with, I think it took three heats to finally drive the pin out.
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