Foxbody Door Hinge Repair Nightmare

I found a great pictorial article on the net for how to repair your door hinge. I tried it out this weekend and the whole project became a nightmare.

I was able to grind off the head of the pin on the top hinge and use a punch to drive the pin out but when I went to cut the hinge pin on the bottom hinge I ran into a snag.

I was using a dremel tool mini cut off wheel and the head of every arbor I had broke (3 of them) after about 10 seconds of use.

I have to find a new approach. What have others done?

So far I tried a hacksaw and an air saw with no results since the pin is hardened.

I found the right tool for the job...

Dremel has a new EZ Lock arbor that uses cut-off wheels with a metal reinforced center. I was able to cut through the lower hinge pin with a single wheel.



I was able to install the new pin easily into the the top hinge but I am having trouble getting the new pin through the bottom of the lower hinge. I tried driving the pin down the hinge the last 1/4 inch using an iron rod and a 4lbs hammer but so far I only succeeded in bending the arm of the lower outer hinge.

Does anyone have any tips on how to proceed?

Does everyone have as much problem as I have had? I have 8hrs into this door hinge repair and I am still not done