RE: buckled ca hinge
The electric slot cutter does a fairly good job of removing just enough material that this is not a problem.
If you can do this right up against the existing hing, if anything the area is a bit stronger due to the bond to the hinge and the other side that is already hardened.
I will NOT do this with hand picks however. I tried once and I could never get good results attempting to remove the adjacent area.
The Electric slot cutter solves that.
Of course to REALLY play it safe you could pin the hinges too.