>>7915552Never figured out the knee gap. My first one had it and I tried to resolve it, but I ultimately returned him because he had a bum hip ratchet that wasn't fixable. My second one doesn't have the gap or the hip issue. Your best bet is probably to knock the knee pin and whittle down the front inside of his 'kneecap' on his thigh.
Regardless of if you fix the hip issue, there's an alignment issue with his legs and backpack that will keep the truck mode slightly bent.
>>7915557You could, but you'd make the hinge mounts on the grey piece very weak in the process. I'm not keen to try it, but it should work in theory as long as you're gentle with it going forward. I see what you're thinking, and in your position I'd knock the pin and do a dry run to see if it'd fit right. I'd also expect it to sag a bit since you're losing the tab mechanism and the hinges won't be in a friendly place for gravity.
