H-bar assembly hole alignment

I just received a new H-bar and I'm trying to assemble the top crossbar that slides into the two plastic 90-degree connectors. On one side the crossbar won't slide in far enough for the screw assembly hole to be fully exposed. It doesn't seem to be the crossbar itself, because I can flip it around and both ends will line up fine in the other 90-degree plastic connector. Any suggestions on how to proceed?

Must be something in the elbow?

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Matt Miller
Former - Director of Parts and Accessory Sales
Warranty and Technical Support
Hobie Cat USA
(Retired 11/7/2022)

After inserting the center tube into the elbow on the side that's not aligning, I'd put the elbow fitting on the floor and give the center tube a firm push to get it seated properly. You can even tap the center tube with a rubber mallet or a block of wood to help get it seated. Sometimes in the molding process there's a little plastic built up in there and it makes for an extra tight fit. You may also chose to enlarge the hole slightly in the aluminum center tube to help it align with the hole in the elbow fitting if it's incrementally off. The aluminum drills very easily. Apologies you're experiencing this, we'll make sure we look into it with our supplier.

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Howie Strech
Parts & Accessories Product Manager
Hobie Cat USA

Had to widen the hole in the tube. Glad to see this officially sanctioned in case there is a warrantee issue.