Coded

Due to the fact that each hinge has its own location, and you can't mix and match them, every hinge half has a numeric code on it that identifies it and corresponds to its mate.

Starting

The first step is to remove the studs. If one is doing a quick hinge refurb, this isn't necessary, but since I'm doing a full refurb, with fresh paint, I have to remove the studs.

Pin Removal Tools

Using a small diameter bolt and a 2lb. sledge hammer, I knocked the pins out and into a hole drilled into a 2x4, taking note of the direction of the pins.

Pin Head

You knock them from the bottom of the hinge through the top (it's pretty obvious which direction this is because the head of the pin is ground flush with the hinge and the bottom of the pin does not go all the way through. Here you see the head of the pin, starting to come out the top.

Hold It

Because you're dealing with a heavy hammer, and a small driver, it's a good idea to use a tool to hold the driver as you strike it. Also, bending the hinge 90 degrees will make it easier to keep in the proper orientation.

Separated

The pin is driven out, and the hinge halves separated.

In a Row

All of the hinges have their pins removed. Next step...

Bushing Removal

...Is to remove the bushing. An 8mm valve stem, ground on the end to make it slightly under 8mm (8mm being the internal diameter of the hole that the bushing is pressed into) works well.

Done

All of the bushings are removed. It's pretty easy to tell which hinges are on the door less used. Note the bushing at the bottom: It was worn all the way through, and caused the bushing hole to become slightly oval .

Wheel Off Paint

A wire wheel on a bench grinder works wonders at removing paint! Just look at that shiny hinge half down there!

Coated

A full coating of POR-15 should ensure that these hinges don't prematurely stain with rust.

Flat Space

Pressing in the bushing is dependent upon the flat of the hinge. Set this up to be horizontal and you can't go wrong when you drive the bushing in.

Buffer

Here a piece of Delrin buffers the blow between the hammer and the bushing. You don't want to deform the bushing with a direct blow...

Pressed In

Determine the top of the hinge, and drive the bushing flush.

Pin

Once the bushing is in, assemble the hinge halves, align the holes, and press the pin in part way.

Driver

Once the pin head reaches the top surface, it requires a lot of force to drive the pin down. Use a driver to prevent marring the top surface of the hinge, and a holder to prevent marring the top surface of your hand!

Driven

The head of the pin will sit proud of the top surface. The second hinge from the bottom shows the bottom of the hinge, and what the pin looks like from that angle.

Grinding

To get the heads of the pins flush, grind them off. Be careful not to grind into the hinge.

Flush

Ground off flush, and ready for the last step.

Painting

Flush surfaces coated with POR-15 and ready for paint.