I'm trying to replace a broken boom cap on a Hobie 18. Got several (used) replacement parts shipped in, and drilled out the rivets to remove the old cap.
However, none of the rivet holes in any of the 3 used replacements I've tried line up with the holes in the boom itself. And on closer inspection, none of them match up with the others either. It's like each of the parts was drilled by hand, separately. Worse, the holes are all just far enough out of alignment that I can't force them, but just close enough together that trying to drill new ones would leave me with giant oblong holes that a rivet wouldn't grab onto properly.
Looking in the manual, and on old seller sites, it seems like the boom caps always came pre-drilled. So I'm trying to get a handle on what's going on.
Figured I'd ask if this was a standard/common thing, and if so what some suggestions for how to retool things so that I can attach the cap without compromising structural strength of the join.
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