Chris,
are you being an animal and dogging up the screws so they don't go in straight? Honestly, if you do it as it so the screws are straight, don't need to be tight, just touching on the pertruding pin and alls well.
If this is the case, try doing like Dan says with dremeling it, then also put a washer on the screw and it'll be bombproof.
Mines built with pertruding hinge pins and screws just touching, no washer.
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www.jespares.com
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