1 1/4" bimini frame onto a 1" rail?

Current bimini and rails are 1". Qwest pontoon. How can I install a new 1 1/4" bimini frame on my 1"rails?

Your correct that most of the mounting hinges are for 1 1/4” frames.
However, with that in mind, you can get creative.
You can order the deck hinge in either metal or plastic.
Using the metal will take more effort, but the plastic hinge sides extend to cover cap the rail. I would go to home depot and buy flat stock aluminum, that is just the right thickness to create a gap filler. Hopefully a piece on either side of the rail, so your new fitting is centered allowing you to use the same holes.
I would be careful about drilling extra holes in the rail, since drilling holes weakens tubing.
I personally would have that spot welded to the railing, then slip your fitting onto the new thicker mounting location and attach.
I would of course have to see what is there to give other opinions, but it can be done.
Another possibility is to have the spacer aluminum pieces welded to the metal hinge fitting to create a cradle cap.
Good luck with your project.
Best Regards,

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