I looked into doing a more scale like Freise type aileron but I decided to go with my original pocket style hinge for the following reasons.
1. I want to make the control surfaces removable.
2. I want at least a 7/8” from the center to the link on the aileron horn.
3. I want it to look scale without having a big horn sticking out the bottom
4. I want it to be strong and ridged enough to not create a possible flutter situation.
I had to rule out using the Robart hinge arrangement shown above because it would not be removable and I feel that it would not be adequately ridged enough for my comfort. I made a layout using my tubing method with a 1/16” music wire hinge and it requires a large horn sticking out the bottom. I was not too keen to use an internal link above as it would be a short through from the center to the link and would be more difficult to fabricate.
The next three layouts using the original pocket hinge are to scale in Solidworks. It gives me a horn that does not stick out too far while being easy to attach and with a faring I could hide it nicely while satisfying all my requirements.
