Brian,
Thanks for this great how-to post. I had just finished rebuilding my driver side door hinges and had the same oversize pins. Mine measured .347. I used an old machinist trick of stretching an 11/312 reamer to make it cut oversize. It worked, but what a pain!
Another problem you may not have gotten to yet, is that the need to adjust the hinges with a torch. The top hinge needed to come out 1/8".
After carefully heating and adjusting to get exactly 1/8" out, upon reinstalling the door now need to go 1/8" forward (beyond the adjustment). Anyway after a couple install, remove, disassemble the hinge, heat, bend, reassemble and reinstall cycles the paint is toast.
Thanks for all your help.
Dan
