Alan,
Okay, let me see if I can make it clear.  First, the two parts do not fit together well.  The part that slips through the bulwark from the exterior, let’s call it the pipe, does not meet well with the part that is inside the bulwarks.  Let’s call it the flange. 
They do not meet well in two ways:

1) the end of the pipe that is supposed to meet the flange is not on a smooth plain (sp?).  So when I hold the two pieces together up to any light, I see big gaps between them, mostly the left and right and above.  The bottom of the pipe and flange met pretty well.

2) They also do not fit well together such that they slip sideways or rotationally a bit.  It seems to me the shape of the pipe where it is supposed to meet the flange is not shaped right to fit into the “ledge” on the flange (see the photo).  (or maybe it is the other way around!)  This might be remedied if the two met without any gaps.  But I thing that joint could be improved.

I am afraid that grinding/filing the pipe so that it is in a smooth plain will remove too much pipe that then I will not be able to have them join well and keep out water.  It is that gap that has caused terrible chafe damage to my mooring bridle.  The thickness of the bulwarks begins to play a part.

You will see in several photos that the holes in either the pipe flange or the interior flange are not centered.  One is even encroaching on the seat for the pipe.  Another photo should reveal how the rods are not parallel.  Now I can appreciate that putting those holes in and also through the bulwark would be a challenge because the outside and inside surfaces of the bulwarks are not parallel and the hawsepipe is an oval!  How do you aim the drill bit?!

I hope that helps bring meaning to the photos.

It is interesting that you mention rods made of silicon bronze.  I have been lead to believe that copper rods are what one wants.  Copper is what I removed.  Copper can be peened without heating.  Bronze is much harder and does not peen easily.  However, the quarter inch bronze rod might be just what I would want if I were to add bronze to the inside lip of the pipe to give me enough material to shape and fit the pipe to the seat in the flange.

Have a happy new year’s celebration!
Clifford
s/v Voyager
Tashiba 40 #173
Jamestown, RI