Hi Bob,
How are you getting on with this?
I tried to knock the pin out of a new britpart TD5 hinge and found that the washers were actually inserts or sleaves which sit inside the pivot pin hole in the door half of the hinge. The pin was jammed solid into the sleeve so needed to be drilled out from both sides. I have a new genuine hinge which looks the same but don't want to destroy it to check. Are your hinges the same?
G