At around 500 flight hours I was getting wear on the cowl hinges, one of my end “eyes” had worn through and would no longer support the hinge pin. The thought of replacing the hinge, riveting and the associated painting was not appealing to me.
The replacement hinge material is from Aircraft Spruce, this material is better than the hinge used in the kit. I Cut a piece of the new hinge with the required “eyes” (3) to replace the worn out ones, and added the 1 more flat area length to extend to the next good eye. I located the rivets and made relief holes in the new hinge piece. I used a vice and wood block / mallet to slightly bend the offset to the eyes so they would line up with the existing hinge The new piece was mounted “upside down” so the natural angle of the eyes were toward the outside. I used a hinge pin to align the new piece with the existing hinge and checking the freedom of the hinge pin. Scuff up the face of both hinges and JB Weld them together, clean up the excess glue and paint as necessary.
The hinge material 3 feet, Aircraft Spruce PN 03-00052-3, MS20001P3