ORIGINAL: Crash-N-Burn
I have been working on finishing my plane now for a few weeks. Each time I think I am done with it, I read another thread that informs me of other areas to consider fixing or at least assessing prior to flying... Now it is broken ribs and additional carbon fiber rods on top of the stab.... My real concern is the pre-drilled holes for the aileron servos ... they seemed to be too large for my 5625 servo screws and needed some strengthening when I started... but, now I am thinking of drilling them out, installing a hardwood dowel plugs, then drilling to the proper size ( I don't want them flying out and ripping off the ailerons prior to me landing)... also I am removing the CA hinges and replacing with pinned hinges.. after that, I will just pray I have looked in every conceivable area for problems.
Why not just use larger screws? A #2 screw seemed to work fine for me after putting a drop of thin CA in the hole and letting it cure. If you insist on drilling the holes out, don't use dowels...use short pieces of inner nyrod (the fluted yellow plastic). CA it into a 1/8" hole. Servo screws bite into the plastic and stay very tight.
If you have a decent setup (good servos, proper linkage geometry) and seal the hinge gaps, properly installed CA hinges should work fine. I agree that pinned nylon hinges would be 'better' but considering the trouble you'd have to go through to remove the CA hinges, it might be more trouble than it's worth. If it flutters, it will break the TE anyway...CA hinges, nylon hinges. Keep it light and fly slow.
-Tom