Replacement door hinges without bushings?

I used the RestoRick kit with the oversized pin on the hinges on my '66 Dart (as described in the thread). It worked perfectly. He even sells the proper reamer - at least, he used to. I'd reach out to him if you want to do it yourself. You may find the roller pin(s) to be badly worn though. I did have to make a couple of those to replaced the old ones. Alternatively, you can press them out, turn them 180*, reinstall, and zap a weld on the end to hold them.

Door hinge rebuild - Resto Rick Rebuild Kit