ORIGINAL: darock
I always try for zero hinge gaps
This is actually a bad idea, and a leading cause of hinge failure.
Since I can't show you, you'll have to try to imagine this...
Ok, you have an Elevator hinged to a Stab - but not glued.
You press the elevator against the stab so there is no gap.
Now, flex the Elevator both up and down about 45 degrees, then bring it back to level.
Do you see how now there will be a slight gap? (If you don't think it will happen, try it with a few pieces of scrap)
This gap is essential!!!
Flexing the Elevator up and down caused the hinge to pull out slightly. The hinge was PRIED out of its slots by the LE of the Elevator pushing against the TE of the Stab.
Now, if you do not allow for this gap, every time the elevator moves, it will pull on the hinge thereby stressing it. This can VERY LIKELY lead to an eventual hinge failure.
SO LEAVE THAT GAP!!!
This is why, if you read my "How To" you will see that it says to "Flex the hinge MORE than it will move in flight" and with the hinge in THAT FLEXED POSITION, add a few drops of CA - That way, when it returns to center, the gap will be set by the motion of the control surface.