Hinge Pins for Smaller Aircraft
 

For those of you who like to pin hinges, here is a method for smaller hinges.
Key a toothpick in your rotary tool of choice. Dremel on low speed wont burn your finger. Press the toothpick with your finger against a sanding bar until the desired diameter is reached. Slice to the length needed, and with needlenose/tweezers, dip in glue and install in your pre-drilled pilot holes.
Mini Telemaster was #55 drill size.

RE: Hinge Pins for Smaller Aircraft
 

I've never pinned plastic pin hinges, and find it unnecessary if the surface of the hinges are roughed up. Just make light cuts on surface of the hinges with an x-acto knife. About a dozen cuts on each side and the hinge is ready to epoxy in place. Just remember to lube the pin with vasoline before gluing in place.

While I've never had one installed this way fail to hold, or or seen a pinned fail either, I've seen plenty of of unprepared hinges pull free.

RE: Hinge Pins for Smaller Aircraft
 

Many years back, I remember a plastic hinge offered that had raised ridges which were angled to act like barbs. Form a tight slot for them, and you would actually remove/damage the balsa if you removed or repositioned one. Those still got pinned!
Klett made great hinges, but I believe they are no longer in business.