How about trying the Hayes plastic hinges, guys? (Used to be Kraft-Hayes before Phil Kraft retired). Cycle them back and forth to set the plastic, scuff them up, install with slow-dry epoxy (15 min. ok), and you can have near-zero hinge gaps, and hinges that will last for years. I have been using these on all my "serious" airplanes for some 26 years with zero hinge failures. As I understand it, they used to be the "gold standard" when Kraft radios and items were popular.

Clair