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Old 04-30-2002 | 03:31 PM
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majortom-RCU
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From: Merrimack, NH
Default Hinge Choice For Senior Telemaster

I like Klett or GP or any nylon/plastic hinge with a steel pin, something that swings with close to zero friction.

I cut my hinge slots with a 1-1/4" rotary saw blade (from widgetsupply.com) mounted in a drill press for best straight hinge-line (although I have done it with a hand-held drill). The blade thickness gives a moderately tight friction fit for the hinge tabs. Before fitting the hinges I cover the mating surfaces with a half-inch wide strip of covering, just enough to lap over onto top and bottom. Then insert the hinges, drill 1/16" holes through the surfaces/hinges, pin with toothpicks, thin CA just the toothpick holes (the CA will wick down the toothpick and wet the hinge into the slot), clip the toothpicks close to the surface, then sand down the stubs. Now cover both fixed and movable control surfaces. Never any problem with CA wicking into the hinge joints, no messing around with epoxy, waiting for it to cure. Easy to get friction-free straight alignment this way, plenty of strength, no way for the hinge to fail short of total destruction.