Yep, the gap I'm referring to is the distance between the fixed surface and the moveable control surface, (wing to aileron, fin to rudder, stab to elevator). The widest gap might have been 1/16", with 1/32" more typical.

The UCD tail surfaces are double beveled. The ailerons are beveled, but not the trailing edge of the wing. The pre-cut hinge slots were close to the edge of the bevel, but not exactly on the bevel line. The extra gap was needed to get the desired control throws. In fact, I was hoping for more aileron throw, but that would have meant using an excessive gap. (The new hinges will cure that problem.)

On the other hand, I do not expect perfection from an ARF. Even though the hinge slots may have been slightly out of line, and the CA hinges broke, I still consider the U Can Do to be a terrific value!!! I just wish I would have used "doorhinge" style hinges in the first place.