Just got done rebuilding 4 door hinges. I have rebuilt plenty of them over the years.
All of them failed for the same reason as all of them do. Lack of proper lubrication between the pin where it rides inside of the hinge strap. There is an oil in the binge strap for that, but nobody seems to have known that.
Once the pin seizes to the hinge strap, all of the rotation takes place at the very end of the pins at the stamped metal of the hinge body. That is where all of the slop comes from, and very rapidly.
All four of the pins had a close fit within the hinge strap, but the holes through stamped metal hinge body were wallered out.
Over-size pins were needed to restore to usable condition.
So I started thinking about how this could be avoided in the future even if the hinges were not oiled often enough.
If the pins begin to lockup, it doesn't take long for the serrated section under the head of the pin to give up and pin begins to move in the hinge body without any telltale noises or increased effort in opening or closing the door.
My solution is to tack weld the pin to the body so that it forces the pin to continue to turn inside of the hinge strap and hopefully begin to squeak when the pin begins to want to seize so you will know to oil the hinges.
