Either way, this hinge is
making noise and the #1 cause is installation related. If it is installation
related it can often be narrowed down to one of the below.
1. screws not going in straight (if you take the screw out and there is a
crescent shaped gouge around part of the screw hole it means it went in at an
angle) can warp the hinge a bit.
2. If he drove the screws in all the way to tight one after the other rather
than evenly hand tightening each one it can warp the hinge a bit.
Non installation related issues:
1. unreinforced frames or no riv-nuts used on aluminum un-reinforced frames.
2. hinge too small for the door.
3. hinge installed on door that is too heavy for it.
4. door and/or frame not plumb and tightening hinge onto them can cause it to twist
a little.
I suppose they could try to identify exactly where the pop is occuring along the length of the hinge and take a look at the spot it is coming from?
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