It's probably better for this discussion to not call the piece you are making "the hinge pocket". It is part of the A pillar/hinge pillar design. The design of the overall pillar has a recess/pocket for the hinge mounting brackets/flanges. I also has a "pocket" opening for the hinge mechanism to extend into and a nut plate/bracket/gusset. In order to replace your rusted sections of the A pillar, you are making a part that strengthens the pillar face for a VERY HEAVY door that, when opened, is cantilevered/hung off the A pillar. The door has to came back to the same position with little or no sag. Your piece serves two purposes. 1. Provide floating cage nuts and 2. Extend forward to pick up an additional support for the door mounting. It probably extends to the "front" of the pillar and is bolted to the cowl/firewall structure. I don't see that hole in your mock up, I do see it in your original piece. Kevin says the hole was eliminated at some point. That piece you are making would have no real purpose of it is not attached somewhere. So that needs to be clarified here. Refer to the FAM for actual design. I don't have an AD truck or a FAM. The design of these hinge mounting portions of the A pillar are very important and repair should follow the original design and metal thickness.
Regarding your great effort to build the bracket/gusset piece, I see you have bend reliefs (notches) at 90 deg corners. That is necessary. It is not necessary or advisable at the other bends. You are losing strength by doing that.
I realize we all use the term hinge pocket, but it's an opening that has several pieces. Some of which are available, some not.
Right is right, even if everyone is against it, and wrong is wrong, even if everyone is for it. - William Penn
