I had the same problem on my first Integral. I think the pressures seen by the hinge sealing material have a lot to do with the airfoil because I never had the problem before in 25 or 30 years of flying. After three or four flying sessions of the problem re-appearing, I cured it by sealing both sides of the aileron (top and bottom). As I recall, I used Blenderm on the top side and already had monocote on the bottom. On the two Integrals I've built since then, I just sealed all the control surfaces on both sides (monocote for aileron and elevator, Blenderm for rudder). It's been maintenance free. I've just never had a good handle on applying Blenderm.
On the razor blades, do you use a shearing cut where you pull the excess up against the blade, or do you slice it off by running the blade along the edge of the surface? Sorry if I seem to be nit-picking this. I've already tried a bunch of things and haven't been real happy with any technique I've come up with so far.
Verne
ORIGINAL: ArchNemesis
Lots of sharp straight edge razor blades then. And yes, they ''gum'' quickly.
I stopped using clear monokote on the ailerons and elevators when I had the film ''blow out'' of the hinge gap during practice up at Weak Signals. Rather than fold IN to the gap when it closed, it folded OUT in flight...adding significant trim in the process. One minute I'd need 7 clicks of right, the next 7 click back left. Thought I had a bad servo until I landed and luckily saw that the hinge piece of monokote was sticking out. Changed it to blenderm at the field and never looked back.