I think I may try a variant of your suggestion on an Midwest AeroStar I am in the process of rebuilding this week.
[ul][*] I'll drill the perpendicular hole all the way through as you suggested, prior to covering on both the fixed and movable surface, and enlarge one side of the hole to accommodate a toothpick "pin".[*] cover all surfaces (Monokote) prior to hinging.[*] Re-open one side of the hole on both sides of the hinge. For ailerons and elevator, I'll use the lower sides. For rudder, I'll just chose one side.[*] Draw a crayon line across the hinge at what will be the hinge line and insert all hinges for the control surface.[*] Slightly flex the control surfaces and CA through the holes. BTW, this probably has the added benefit that since the surfaces can be kept pretty much horizontal to the floor (==gravity!) as opposed to perpendicular as in typical CA hinging, there is less likelihood that the CA will accidently "drip" onto other parts of the model.[*] After all hinges are in, drill through the hinge from the exposed hole, being careful not to drill all the way through! CA toothpicks or suitable sized dowels. As an alternative, just fill the hole with medium CA after drilling the hole through.
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I realize that this is extreme overkill for this particular plane, but if the cosmetics are not too bad, it might be a worthwhile technique for other planes down the road (or is that down the drunway ). I'll let you know after the weekend how it turns out.