Congratulations on doing the right thing by your hinges,  I want to do what
you did but have not yet found a source for a suitable reamer.
This seems to be the big unknown or the least publicized part of the
operation.
Where did you get your reamers?

Bob,

 

McMaster-Carr:

 

 

.0955  see online catalog page bottom 2325:

High-Speed Steel Decimal Chucking Reamer .0940" To .1090" Diameter Range

$11.49 Each

 

 

See page 3147.  I used 316L 3/32" SS welding rod:

 

316L Stainless Steel— For welding Type 316 and Type 316L stainless steel, and for high-temperature applications. These rods have excellent corrosion resistance.

 

$12.40 for 14 rods in a 1 # pkg.  Each rod has about 30 usable inches.  I got 8 6.5 inch pins from 2 rods (elevator and ailerons) and 6 10.5 inch pins (flaps) from 3 rods.

 

I should note that my fingers were worn out by hand twisting the reamer thru the hinge halves - especially those I left attached to the movable control surfaces.  The smaller 6.5 inch hinges can be "clean-reamed" by putting the ream in a power drill and inserting it from either end save for the middle loop.