Several months ago I replaced both left side doors with new used units due to rust problems. Last month the lower door hinge for the drivers front door was also replaced with a NEW unit. Needless tho say the old hinge had a broken spring resulting in a door that would shut itself. Well, right after the hinge was replaced a ''popping'' sound commenced while opening and closing the door. I inspected the hinges and everything was fine. Upon further inspection I noticed that while opening and closing the door it would move slightly but the hinge was static. How could this be! I then noticed that the lower hinge mount on the door was cracked. This was allowing movement and making the ''popping'' sound right when the door would move past the ''detent'' of the hinge.
This brings me to ask whether anyone else has had a similar experience and how did you fix it? This weekend I will try to weld it. Hopefully some pictures for you guys too.
Please comment and share your thoughts.

Thank you.
Art Berçan
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Teach a man to fish and he will never go hungry. Teach a man to rob a bank, he will never go fishing again.