I fixed the door stay rod pivot joint on my Rabbit to remove play. Over many door openings and closings what happens is the hole that the 6mm diameter factory pin rides in gets worn into an egg-shape. The result is after opening your door, it moves several inches before the door stay "catches" it.
What I did was I found a 1/4" bolt with a non-threaded shank of the correct length (this is known in aerospace bolt specification as the "grip length"), and filed out the hole from 6mm to 1/4" so that the bolt fit perfectly. 1/4" turns out to be 6.35mm, so it's just slightly oversized versus the stock hole, however the original 6mm pin tends to wear down some as well also contributing to overall play.
A 7mm shanked bolt would have also worked well and allowed the egg-shaped hole to be restored even more to a circular shape, but I didn't have one handy (it is not a very common size.) 8mm just seemed too big. I figured I'd start off with the 1/4" bolt I had as I could always enlarge it out more later if I wanted.
I installed the 1/4" shanked bolt with a nylon lock nut, just tensioning it enough so it tightens things up and reduces rocking without causing any binding. I also cleaned the wearing surfaces and greased them up well when I had it apart so it should keep things working smoothly.
I am quite pleased with the result. It no longer makes "snap", "pop" noises when opening and closing the door, and the door stay holds the door open almost as soon as it opens fully.
Combined with fresh door latch pins, this door is feeling almost like new now! (Just gotta save up for some new door seals to complete the effect.
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