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I bought new door hinge bushings for my 68 and they are larger than the original ones.
Is the original size available?
Is my only option to drill the hinge hole for the new bushings?
If so what size drill bit?
Is this something that can be done with a hand drill? My concern is drilling the hole straight.

I would like to share an idea I tried for getting the hinges off without taking the door off. I did remove the fender. With the fender out of the way and door closed, I removed the top hinge leaving the bottom hinge attached and tightened. Once I get the top hinge bushing replaced I will bolt it back onto the door and pillar and remove the bottom hinge.
 

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i would suggest not trying to open up the hinge bushing hole with a hand drill---the holes need to be the exact right size and inline to work correctly
doctordesoto
 

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Sounds like you got the oversize bushings. Standard size are available from me or most Cougar and Mustang suppliers.
 
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