MacGyver, thanks for taking the time out to write this important info. for all to see. Being a home made plane, one should should take into consideration that any part of the the construction could be inadequate. A donated varieze had it's wings tested to distruction and failed at 7 g's-much less than expected. Was attributed to maybe not enough fibre glass in critical areas. One should fly a home made plane of unknown quality with as little g's as possible-slow speed in turbulance, moderate angle of bank, gentle landings.
I'll retorque my pins as I probably used 5-10 foot pounds, and see where they sit. A couple sit now 2 or 3 thou below and the rest are flush or higher. They are very hard to pound out [including the one I made] and need a brass bar as a wooden dowl won't move them.
A note again on making a pin, I would like to develop a modified pin that can be home made just on a lathe. To harden the pin and grind to shape requires specialized equipment. How about a pin that is solid with only a very small recess in the top for the bolt head and bottom nut. This would require longer bolts. It might not look so neat, but would be very strong in shear and not distort. When I first saw the origional pin, it stood out as being poorly designed. It's strength was severely compromised in order to get a neat result. What do you think, MacGyver?