RE: CA hinge idea
OK, guys, here are my results:
I ran two tests, each time making the perpendicular holes in the LE and TE with a T-pin (I did NOT make a hole in the center of the gap, parallel to the LE and TE, as per the RCU method). I used a 1/16" drill bit to enlarge the holes, and get out any balsa dust. I then inserted the CA hinges and created a minor gap between the LE and TE (I didn't flex the joint to an extreme angle, because it kept messing up the alignment of the gap). Finally, I used Zap thin CA with the micro applicator tip attached for gluing. The first time, I dripped it into the holes, but after the second drop, it began to pool in the hole, leading me to believe that it wasn't wicking very well. When I destroyed the test piece, my suspicions were confirmed: not as much of the hinge had bonded to the wood as I would have liked. My second test, though, was a big improvement. This time, I pushed the micro applicator into the hole until it touched the hinge, and then added glue until it began to pool. When I destroyed that test piece, I had a MUCH better bond: nearly the entire hinge had adhered to the balsa. So, I think I have a winner here. However, I'm still open to comments.