So after grinding and smacking the hell out of the door pin I replaced it and the bushings. Only problem now is the ears on my hinge are bent enough that i can't put the cotter pin on it.
Any ideas on how to bend them back with "normal garage" tools?
you could use a long bar and smack the hell out of the ear from the underside. Might have to jack up the car to get some room to swing the hammer. If it's not bent too much maybe a pair of visegrips on the bent ear and just kinda twist up. Never had to do it myself, but that would be what I would try. Post your successful method