Hi Phil,

The profile function and Brickboard mail has been busted for months.
Maybe you have a disposable email address (Gmail for instance) ?
You need to see the close up pictures.
For instance a shoulder bolt of the right size for the cams would not be able
to have a large hex head or it would interfere with the 7MM detent rod.
A threaded shoulder rivet may be too weak for the stress.

There's places near me that supply rod stock in various metals.
I wouldn't think of turning some Brazilian soft steel lag bolt found at
Home Depot or the hardware stores.

Maybe someone has had the shoulder rivets snap off?
Then they might lose the cam and be SOL to repair that hinge.
We need to remove a rivet to get the info to machine a new part.
Then we need to know about staking or heading as you say,
This info is somewhere, maybe the Machinist Handbook.
It will give dimensions needed for the process.
Maybe the shoulder rivet could be welded in? Maybe not?

There's an interesting number stamped on the hinge bracket: L6670
I did a little searching to see if it was a stock hinge for manufacturer
with no luck. But maybe someone can get lucky and find out who made the hinge.
Swedishcarparts is selling the 7MM (approx) detent rod so that was made to be replaceable. Maybe this hinge is used by other car makers, Probably in EU.

You would also think an 8-9" 7MM rod with two 180 degree bends would be
easy to make and sell for a lot less than $45.00 + shipping
The rod mikes up 0.282" but is approximate since it's painted and corroded.
Not your regular size at Home Depot or Ace Hardware.

I wonder if the cams are forged?

You might go look at your driver door hinge and see if the rod shows wear
and if the cams are turning and have any fore and aft slop relative to the
rod. Tell me what's the best way to get lube to the shoulder rivet and cam bore. I suspect once it starts wearing that there's a destructive steel particle grit in there that will accelerate the wear, so maintenance would require cleaning that old stuff out before re greasing. Cleaning was hard enough when you have the hinge in your hand, worse in place.
Using compressed air to clean might make an ugly mess, but maybe there's a way?

Thanks, Bill