Bubba style door pin replacement

[tucsonjwt]

So, I finally got two GM OEM door pins and replaced the pins and bushings in the 83 C20. I had no engine hoist, so I built a platform out of scrap 2 x 4s and supported the door long enough to switch out the pins and bushings.
Some info on this project:
1) Don't buy Dorman aftermarket pin kit - the splined area on the pin under the head is too big - won't seat into the hinge hole. Get GM parts only. The Dorman bushing will work. The OEM GM pins still required a lot of hammering, but did finally seat pretty close to flush with the hinge top.
2) I could not get around removing the wiring on my electric doors. Not as bad for me, since I had screws, not rivets, attaching the bellows to the door. I forgot about the metal plate which covers the bellows, so I had to unbolt the door and install the plate under the screws, then rebolt the door. Do pay attention to the orientation of the connectors on the window motor and door lock actuator - you really can't see in there even with an inspection mirror and flashlight - I had to remove the actuator to see how the connector attached (at right angle to the actuator.)
3) I traced the outline of the hinge on the door with a pencil and that worked well to assist in repositioning to the original location.
4) The door platform worked well, as long as you keep it in the exact same position as when the door was removed. Since I had a two week delay in getting OEM GM pins, my original location was lost, and I had to add a 1/2" plywood shim to get the door back in the right spot. I think the platform might actually be better than a hoist, since the door won't be moving around as much - assuming you remove and replace the pins in one process, not two weeks apart.
5) I used a Dremel tool with cutoff wheel but the wheels I had were not a large enough diameter to clear the hinge and cut the pins, so I had to cut the pins at an angle and go at it a few times from different angles to cut through the pins.
This was not that bad a job, even with removing the wiring, and would have been a lot easier if I had the correct pins to start with. I will get a chance to do the passenger door when I get the rest of the pins.
For info, GM sells the pins in packs of 5 each, and the bushings in packs of 20 each - so, if you order one pin and one bushing you should get 5 pins and 20 bushings. I got 2 individual pins and 1 individual bushing on my order of 2 pins and 1 bushing, so I am waiting for the balance of 8 pins and 19 bushings from OEhq so I can do the other door.
Some pics: