86 carrera check strap pin problem
 

Replacing the check straps on both doors starting with the l/s. The pin holding the arm in place was almost impossible to remove it was mushroomed somewhat. After grinding a portion of the pin I used a punch to drive it out. So I ordered the pin kit from our host and the pin has splines on it and the diameter is to large to fit through the strap and jam flange. I don't want to use the pin I removed as it's a solid steel pin that may fall out after I install it. What are my options here for what should be a simple repair? A bolt and nut, Split pin ?

Thanks

6mm bolt and a nylock nut. Tighten until it quits popping.

First of all, loosen the straps if they are stiff. Search this forum for instructions which require disassembly. I loosened mine so the midpoint “click” almost disappears.
I used the smooth pin with circlip for the hood struts as I don’t really like the gnawing arm movement against the edges of the thread.
Hope this helps.
Cheers,
Johan