Had my lh cowl flap come off in flight. Lucky no damage. Hinge pin just came out. What size is the pin stock? Spruce stocks 089. Is this the size?

.089 will give you .005" clearance fit in a 3/32 hole. Does a 3/32 drill bit fit in the cowl flap hinges?

McFarlane now has cowl flap hinges if it comes to that. Saw them at Airventure.

You know the trick of cleaning your cowl flap hinges and running a bead of RTV across the hinge line? It reduces movement between the two halves, still allows enough flex to open and close, but reduces vibration and wear between them.

The mcfarlane stainless hinges are nice, almost no play in them.

Thanks for the replies, I found some material at work here that fits snug in the hinge. I plan on trying the rtv trick too. The Mcfarlane hinges are definatley going to be in my future. Not fun to hear a big bang in the floor boards. I can't believe there is no damage other than the bent actuator cable

The RTV trick works very well. Make sure the piano wire is softer than the hinge hardness. And I'll just leave this link here in case you want to save a couple hundred bucks on the replacement. You can opt for a slightly thicker gauge than the McFarlane version:

https://www.mcmaster.com/#piano-hinges/=18s696z