Oversized door pin bushings installed :)
 

Huge thanks to Captain Hook and swartlkk for tracking down and posting links to these oversized bushings!

.010 oversized
Catalog :: Total Automotive Hinge Kit Solutions

.020 oversized
Catalog :: Total Automotive Hinge Kit Solutions

About $25 for each kit shipped to your door, I would recommend ordering both sizes. There are no pins included, only the 4 bushings, so if you want to replace the pins too you'll need to get some of those at a local parts store.

They need to be PRESSED IN, for a $25 kit that you have to order online and wait to come in, it's best to take your time with them and not risk warping or breaking them... As suggested by Captain Hook, I used a 1/4" bolt, a nut, a couple washers, and a socket that the bushing can actually fit into, to make a quick "press", and once you get the bushings to line up straight with the hole you're pressing it into, it works like a charm!

I needed to replace my entire door because it was actually warped from the previous owner letting the door sag so bad from worn hinges and they just kept slamming it to shut it... So I figured it was a good time to tackle this, without trying to weld in the hole in the hinge to close up the gap.

https://blazerforum.com/forum/attach...ine=1424784928



As usual, it was just the upper hinge holes that was opened up. The upper is the only place I needed to use the oversized bushings in, I actually used original replacement bushings in the lower hinge (door side).

I also took the time to straighten out the bent up hinges and touch up the paint, it was all scratched up, from who knows what... did the door jam and the lower door sill area, just with some color matched spray can paint gotten from a local parts store.

https://blazerforum.com/forum/attach...ine=1424784928

https://blazerforum.com/forum/attach...ine=1424784928

https://blazerforum.com/forum/attach...ine=1424784928

https://blazerforum.com/forum/attach...ine=1424784928



https://blazerforum.com/forum/attach...ine=1424784928

https://blazerforum.com/forum/attach...ine=1424784928

https://blazerforum.com/forum/attach...ine=1424784928



Although it may have not even been needed, once I got the new oversized bushings into the top hinge holes (which by the way I ended up using a .020 in the lower and a .010 in the upper, so it was a good thing I ordered both kits in my case!), I dabbed a little JB weld into the open void beside the bushings to fill in the gap left by putting a round bushing into an oval shaped hole. Not much, just enough to add a little support on the outside of the bushings.

https://blazerforum.com/forum/attach...ine=1424784928



I put a little lube on the bushings (along the insides and flat lips that are going to contact the other half of the hinge and pivot on), lined the door up, and dropped the pins in.

https://blazerforum.com/forum/attach...ine=1424784928



The little effort to touch the paint up made the door jam much more pleasing to look at in the end lol

https://blazerforum.com/forum/attach...ine=1424784928



All that was left to do was make the new door match by removing all the pinstriping and side moldings :) which I'm still in the process of, but at least the color matches lol

https://blazerforum.com/forum/attach...ine=1424784928

https://blazerforum.com/forum/attach...ine=1424784928




The door lines up SOOOO much better and closes much better now, and best of all, actually seals!

Nice!!!!


Digging that light bar too!! Where u get that?

eBay! :) 40" for $100 on the roof, 24" for $50 on the brush guard. Not top of the line by any means, but GOD do they throw some light!

https://blazerforum.com/forum/attach...ine=1425069895

Very professional looking, fantastic job! Nice write up with good images! All for $50 and a couple of hours work!

Blazen,

How did you get the spring back in the door? I can't for the life of me get mine back in. Tried a number of ways such as a vice and wire ties to compress it enough to get it back in the door

Thanks

tenor - Summit Racing - door spring tool - part # wmr-w84603 - $9.23 plus shipping

Cool thanks odat.

Didn't realize it was such a simple tool

I know this is 100% off topic, but can you send me a pm about how you mounted that top light bar? I've been wanting another one for the roof, but I want to know I have a good way to mount it before spending the money on one.

Dude, this thread was just in time. I logged on to ask if anybody had used this kit and I saw your post. Nice write up! Thanks!

I was wondering if there was a better part like this one, because I have replaced my bushings at least twice and they only seem to last about a week before you can tell that they are broken.

OK now some simple questions. Can't believe the timing, I have to replace the ones on my daughters Blazer about every three - 4 months and did it today again. Alway the lower part of the upper hinge, I buy the kits at the local auto store for 7-8 dollars but they don't last because of the oblong holes. Today I also used with the new bushing some industrial epoxy I use for work, gets hard as steel and it can be grinded, drilled and tapped. I've rebuild air compressors with it and have one in my garage that was junk for 5 years now so it's good stuff.
I see it says how much bigger then the original but how big is that?
Also did you have to ream your holes out any and if so how did you get in there to do it. The one I replaced today is so loose I pushed it in with my finger with no force at all so one of these kids is in my future!
Also I assume these are a little thicker f the outside diameter is larger and the pin the same size? Are they made of the same material?

The new bushings come in two sizes: .010 & .020 oversize. Best to have both on hand before starting the job. The bushings are splined so they do not rotate when the door is opened and closed, and they must be pressed into the hinges. Try the .010 bushing first, if it's sloppy, use the .020 bushing. Reaming should not be necessary. The hinges MUST be square, and the pin should slide in easily, with no binding, BEFORE hanging the door. If the bushing fits too tightly in the hinge, the inside diameter will be distorted and the pins will bind. The pins are splined to the other half of the hinge so they rotate when the door is opened and closed.

Toocute350
 

I have the same problem with my driver side hinge on the door it self.Not the hinge on the cab.I talked to a guy named eddie awhile back at total automotive.I told him my situation he told me about the over sized bushing size also.The top pin hole on the driver door is ovalon.I will try and get a oversized bushing in it and then fill it in with jb weld.Thanks for posting this matter.You think GM Would have made smaller hinges like the newer gmc and chevy trucks.I guess having power locks and window`s add alot more weight than normal but still.:)

I repaired mine three months ago and used DuraCraft Epoxy also and so far so good, and that's with my daughter using it. :icon_razz:

I just had to replace the passenger front ones last weekend. That side is still using factory sized bushings, the tops completely fell apart... The driver's side with the oversized bushings though, still like new almost a year later :)

Where did you get the over-sized bushings? Links please.

Links are in the first post, but they're dead, looks like they no longer produce them any more unfortunately... shame too... seemed to be the only solution short of welding the bushing hole shut and redrilling it for a stock bushing...

Part numbers from the links above were as follows:

A quick google search should give you some purchasing options.

I have updated the links in the OP as well.

Oh nice find, I actually could not find them! Thank you very much sir! :icon_worthy: