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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...

Just use the "ordinate set" command and it should work just fine. Select your origin, your features, then r-click, continue. Hope this helps.