Thanks Lizbeth! I'll proceed with my first plan & acquire some 1/4" stainless bolts that are slightly longer than the zinc bolts that came with the repair kit, to allow for the spring flex. Since the door opens much more easily now than with the PO's arrangement, I wasn't sure if the 'friction' was caused by the tight fitting 5/16" bolts he used or the 'rounded' nuts he'd substituted for the brass ball. Probably a combination of both. Also, he had no springs at all on the pins to allow for hinge 'shift' when opening the door. Thanks again for all help/advice.