Fixing wear in early AI aka-crossbar hinges.

[Deefa]

First major DIY project on the 2009 AI was to fix the play from wear in the aka to crossbar hinge. This is caused by wave motion wearing the aluminium aka bores against the far stronger stainless steel hinge pin - makes a good bang in chop, and doesn't feel all that nice. This is expected wear on an older AI, later models use a different hinge system (that has its own set of issues)
Copied a bloke on the hobie forums, obtained:
stainless steel seamless tube, 5/16" x 0.028" wall & JB weld.
Using hacksaw & HSS countersink bit, cut lengths required (8x 12.8mm, 4 x 65mm) and countersunk the inside of one end on each length for easier pin installation)


Drilled out the nominally 6.5mm bores to 8mm (this was the hardest part of the job, aligning the two holes 65mm apart on the aka side)
JB welded the stainless steel inserts into place, cleaned the insert bores & used a 1/4" straight rod to align the two sides on the aka arms.
Afterwards (just the aka arm):



Test sail showed a massive improvement - the aka hinges have no play and don't sounds/feel bad.

If you are contemplating an older AI - this and removing the corrosion/reinforcing the aka to hull mounts are the two things to schedule into the 'restoration'.