I just welded a set in yesterday. It's a challenge by yourself, easier with two people.
Here's the FULL start to finish:
1. Remove the rear trunk lid and set aside.
2. Unhook the torsion springs and remove the hinge arms from the car.
3. Grind, clean, prep the area to weld. This includes removing the old busted hinge and repairing any cracks, holes, or tears in that area. Now everything is clean and ready to accept the new piece.
4. Bolt the hinge arms to the trunk lid. The arm has oval holes for adjustment. I like to center the bolts.
5. Carefully slide the trunk lid into place on the car. It's possible with the hinge arms in place, but it's a tight fit. Having a friend and communicating really helps here.
6. Use the shoulder bolts to attach the new bracket to the hinge arm. You should now have a fully assembled hinge that's ready to weld to the body.
7. Now the important part. Align the trunk lid with the body. Make sure the rear/trailing edge matches and make sure the height matches. Having the seal in place helps hold things and having a friend around really helps. You want to get the trunk lid into 'perfect' position.
Approach this step as if there is no adjustment and where you weld it is where it is going to sit forever.8. Having a friend hold it steady (remember - perfection) tack weld the hinge bracket to the body. You'll need two or three good tack welds to hold it into place. On my Lincoln Weld-Pac 100 MIG with 0.023" wire I used the C-5 setting. If you've removed the torsion springs you can access both sides of the bracket to tack them into place.
9. Carefully remove the shoulder bolts that hold the hinge arm in place. Remove the rear trunk lid (you can remove the hinge arms from the lid if you want).
10. If you bumped or knocked a hinge bracket out of place at this point GO BACK TO STEP 3. Remember - perfection.
11. Completely weld the bracket to the body and add some weld to secure the screw boss to the sheet metal. That center section has been known to rip clean out with only the existing welds.
12. This is one of the most important steps of this process. Clean your shoulder bolts and the holes in your hinge arms. Rust on these parts is what makes the lid hard to open and places stress on the brackets, causing them to tear. Clean with sandpaper until the rust is gone. A bit of sand paper taped to a drill bit makes a good way to clean out the hole quickly. Also, lightly chucking the bolt in a drill (don't mess up the threads) will spin it for quick cleaning with sandpaper.
13. Lubricate the shoulder bolts and re-attach everything to the car.