OK, so I made the poor decision to take the door off to work on the skin. I had to drill out the screws from the hinge to the pillar... Could not remove the pins.

What is the best way to get this door re-hung? Since best can be interpreted in so many ways - this is not a show truck, and a simple durable solution is ideal.

Will a carriage bolt tack welded to the door hinges and nuts on the back work, or is that too simplified? I am guessing the tolerances between the hinges are not close enough that the head of the carriage would prevent the door from closing, but I could be way wrong.

From feeling around, it seems like a caged nut was used for the screws from the factory, is this true? What other ways of fixing these has worked for you guys in the past? Is it worth cutting an access panel in the sheet metal to get to the back side to weld something new to the back to mimic what was there? (I can not manage it from inside the cab)

Thanks in advance! Hopefully I am over-thinking this one.

 

hinges are bolted to a flat steel triangle that is not hard to get out. Look into the jam from under the dash and you will see them, pry back the retaining tabs and you can remove them for repair. These pics are from my truck #1 build thread. Heat the broken pieces and unthread them, then chase the threads with a tap. I replaced all my bolts with stainless tapered allen head style bolts.

 

Awesome! Thanks. I see what you are talking about after some contortion-ing... Seats coming out for the repair.