Thanks Kurt,

Turned out it wasn't as much as I thought initially. It wound up to be a little less than 2mm.

I haven't cut slots for hinges in probably 10 years, but I did the elevators last night and they turned out great. My hands are getting less shaky as I move along....LOL

Btw Nathan, when you say "seal the hinges", do you mean putting covering along the entire length of the top of the aileron where it meets the wing? I think my buddy (who's plane it is) said he read that somewhere. They turned out pretty tight, enough to where a T pin fits thru and allowing full movement up and down.

B