I got my welder out today and had at 'er.
It is really tight and you only really have access to the top and the front side of the hinge.
I put a layer of masking tape and then a layer of metal duct tape to protect the paint from weld splatter.
My first try broke after a few short (maybe 10 degree) swings of the door.
I welded again and applied my penetrating oil (50/50 mix of acetone and tranny fluid) and swung the door (10-15 degrees) until it broke again.
I did this several times, each time getting a few more degrees of swing.
Eventually, mud started to drip out of the bottom of the hinge.
At this time I got out my air hammer and low and behold the pin started to move up. A couple of hammer it up and down and it came all the way out.
It was very pitted where it was located in the center part of the hinge.
With the pin out I could move the door and get much better access to the hinge. I ground off the previous weld attempts and ground the broken part of the hinge, now that it was free of the pin.
So, with both end of the break cleaned up, I reinserted the pin to align everything and I did a final weld.
I then removed the pin again and with door slightly askew I ground down the new welds to neaten it up and make it ready for paint.
Finally, I applied my favorite anti-seize and hammered the pin back into position.
Success. The door now swings freer than it ever has.
I got a little damage to the door paint from the seized hinge rubbing on it.
I'll pick up a can of matching paint and fix it tomorrow. For now the primer will protect the metal.
I have a new hinge in the mail. We will see what I get and may or may not need to install it. Time will tell.
