Forgive me for the following basic list of suggestions, you have something weird going on and i cant figure it out!
We do low pressure seals all the time, some leaking parts are a result of as little as a hair across the seal surface.
Could there be loose contaminats disrupting the seal...
Why 2 o-rings? Remove one and see what happens, this will cut your required compression force in half.
A thicker plate would do some good, over that large surface even a relatively low pressure is a large force.
SP
I would use the maximum material modifier (as shown), so that if the pin is on the small side you get some bonus tolerance on the perpendicularity.
Enjoy!
I have attached what I would do. This method does control the centerline as perpendicular within a cylindrical zone, and allows you to define the size, alse you could use this axis as another datum (but not needed).
Hope this helps. I am no expert but there is a very similar example in our...
I am looking for a small flow divider for a piece of test equipment. Also corrosion resistant materials are a must.
The goal is to split a 40 psi supply line (<1gpm) of surface disinfectant (lysol, clorox, etc) evenly between 4 spray nozzels. Currently i am using a needle valve in each of the...