After more observation, I now see why the hinge sealing is causing me problems. I installed the Robarts with the hinge knuckle flush with the leading edge of the aileron. This places the actual pivot point behind the leading edge of the aileron. As the aileron moves, the leading edge moves up and down quite a bit. If the covering seal is tacked down all the way, it has to stretch or be pulled up a little to allow movement. It would cause the same problem if tape were being used. I tried a little strip and attached one side completely and only tacked the edge of the other side. This allows it to move with the aileron. Doesn't look quite as nice, but should be functional. Thanks again for all of the replies and ideas.