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OK. I just spent 30 minutes heating and popping gwen apart and working on the joints. As I suspected, the ratchet nubs are WAY too big, causing the hinges to be much tighter than they probably should be. I shaved all of the ones in a shoulder down by about half and they were still tight enough to wrench the arm off, so I went back and cut half of them completely off. Same deal with the ankles, now I can get more than two positions out of them.
The hips are a different story. First off, the actual nubs are much harder to get to. There's a set that's covered by the thigh no matter how you rotate the peg, so unless you can wrench it out completely it's still got a spot where it locks hard. The wild thing though, is that the front of the pelvis part where you plug in the sash or whatever straight up has a hole in one side. You can just pop off the piece and see for yourself, it looked exactly the same in all of mine so I'm thinking it's a mold problem. That's probably not doing the loose hip swivel any favors.
