RE: What diameter
I use robarts all the time. In most cases I use the 1/8" unless the control surfaces are quite thick. Make sure you put some oil or vasoline on the knuckle. I also use Pacer hinge glue but I know lots of people that use the gorilla expanding glue. I just don't like the mess. BTY I have never had a hinge fail using the hinge glue. Also, water clean up. When I install the hinges I take a 1/4" dowel and wrap a piece of sandpaper around it and then I sand a small circular slot where the hinge is going to go. That will allow the knuckle to fit into the slot so that you have a very small gap on your hinge line. Just my 2c