The top hinge on my garage entry door is offset about 1/8", which is preventing it from closing and sealing properly. The manufacturer will not honor the warranty without proof of purchase, which I do not have (it has been three years). I was hoping to find a 4" hinge with opposite screw pattern and installing it in the proper location, but haven't had any luck finding one. I was thinking maybe filling the existing holes would JB Weld then drilling new holes just beside them to properly position the hinge. Seems like this would work. Any suggestions? Offset hinge shown in top image, normal hinge on bottom.

 

Abandon the original holes. Drill and counter sink new holes in the hinge in a different location.

 

Trying correct a hinge location by a 1/8 inch is nearly impossible. The screws will just drift into the old holes, even if plugged with JB weld or similar. Relocating the hinge is you best alternative. However that will require mortising the door side and the frame side. Not hard but tedious. A router will make it fast and easy. But a good sharp wood chisel will do a good job. Very careful measurements is key.

 

Okay. I was thinking that would be too close to the existing holes. Drilling alternate holes through the hinge makes sense. I'll give that a try.

 

Drilling new holes through the hinge worked . Doesn't look the greatest, but it corrected the alignment.

 

Boy, you did have to move it a fair bit.