Thanks for the info Luke. I have put the robarts into the rudder and elevator and they turned out great. If I drill 1/8 holes 1/16th down from the top edge of the aileron and the trailing edge of the wing, that implies that the head of hinge will actually be above the top edge of the hinge. Am I understanding this correctly? When I did the elevator and rudder, I installed the hinge into the trailing edge of the surface and left the head of the hinge exposed to the point that the hinge could be flexed 90 degrees in both directions. I then installed into the leading edge of the control surface and gently persuaded the head of the hinge into the control surface, thus creating the required recess. I ended up with a gap of probably less than 1/16, actually just enough to allow the designed 45 degree travel in either direction. Do I approach the aileron in the same fashion? I would think that even after creating the recess, the head of the hinge will be clearly visible from a top view of the wing?
Thanks again for your patience and assistance. I don't want to screw this up.....