I did a hinge repair on a old 68, what I did to get the pin in is resize the lengths of the pins. Trimmed the bottoms about 1/16th to a 1/8th shorter, and redressed the bottom of the pins, smoothed them out with 400 grit. Installed them and didn't hit the door opening. The pin was about a 1/4 inch longer the the hing at the bottom before trimming. And still stuck out about a 1/8th after trimming. Worked like a charm. Just don't flute the ends as much. And polish them up with 400 grit. But you gotta seat the pin in all the way too.
My guess is from the bushings being worn the hole is out of shape. Happens often. When bad it can let the leading edge of you door hit the hinge when open all the way. Cure, Weld the hole and drill it to correct size, or replacements are good also. There is a lot of weight hanging on those long door hinges.
