ORIGINAL: fstevenj
1. What size hinge points should I use?
Either the 3/16 or the 1/8" will work, but I would use the 1/8"
2. Obviously I have a Manufacturing Problem, What could it be? The hinges didn't bind, the gap was not sealed, I didn't notice any flutter, but not sure I could recognize it.
Manufacturing problem? Doubtful. It sounds more like an installation problem.
3. How can I fix this design problem? Are the hinge points more robust?
While the elevator is still attached, draw 3 lines (each side) on the bottom of the stab and elevators. Then remove the elevators and use the lines as a guide for drilling the holes for the new hinge points. Make sure that the holes are centered top to bottom and directly on the drawn lines. If the holes are slightly off, you can make them larger and fill in the excess with epoxy.
4. I did notice that at full elevator motion I have a little torque in the stabilizer could there be a slight alignment problem? I would think the outside would shear off first if this is the problem.
There COULD be an alignment problem, but there's no telling where it would break without seeing it first hand.
5. Also is there a potential for overspeeding the aircraft such as powering though a loop instead of letting off power at the top of the loop? I'm just a beginner and not doing too much to the airframe.
Doubtful with an LT-40 unless it's WAY overpowered.
7. The design has a fairly long distance from the last support to the horn, potential issue?
Possibly, Put your hinges about 3/4" in from each end, and one in the middle.