This topic has had a fairly short cycle time on the LML, re-emerging relatively often.  I follow these threads with interest since I tinkered with the hinge issue a couple of years ago.  The result is an all metal solution that eliminates play far better than anything I have seen thus far.  Wear has not been measurable yet, but  I only have a few years and couple hundred hours on the parts.  The details are online at:  http://www.n91cz.com/HingePlay/hinges.htm  
In short, a standard MS hinge is reamed (hand reamer from McMaster) and then a larger diameter pin is used (SS welding rod).

General conclusions:

1.The standard MS hinge extrusion has a huge allowable tolerance for the hole diameter (.005").  Without modification, there is no single pin or insert that will both fit all hinges and not have play.
http://www.n91cz.com/HingePlay/hinge_spec_1.jpg
http://www.n91cz.com/HingePlay/hinge_spec_2.jpg

2.The MS pin is undersized which adds to the tolerance in 1.
http://www.n91cz.com/HingePlay/pin_spec.jpg

2.Wear can be controlled by contolling the pin/hinge tolerance and clearance.

3.Plastics such as Teflon and Nylon are very soft and will flow and deform if subjected to high loads.  
http://www.n91cz.com/HingePlay/sleeve-web.JPG


How much play is acceptable is very difficult to quantitfy.  Certainly less is better, in particular for non-mass balanced surfaces such as large trim tabs.
The following video clip compares the play of various hinge options.
http://www.n91cz.com/HingePlay/Hinge_Play_Test-low_res.WMV



Chris Zavatson
N91CZ
360std
www.N91CZ.com