Another lesson learned the hard way...

After the epoxy cured, we used pop rivets to firmly secure the top hinge to the doghouse �...And the result wasn't great. It took way too much force to remove the hinge pin.

Here we're using pliers to bend the knuckles on the hinge for better alignment.

After some time spent adjusting the knuckles, the hinge pin movement was not improved. We discovered that the pliers were compressing the knuckles.

We took a deep breath... and ordered new hinges. We drilled out the pop rivets, then used a heat gun to get the hinge material really warm, then pried and pulled off the hinge material.

Note that Andy Millin had a different solution to the hinge-pin-bind issue. He found under-sized hinge pin stock at MicroGroup. They sell stainless steel wire in OD increments of 1/1000th. He plans to replace all of his hinge pins with 0.085-inch or 0.086-inch OD wire. (https://www.microgroup.com/product-category/wire/)

10/3/2019   Picture 479