The least amount of gap is always best. I'm not following your problem with the aileron torque rod. However, the beauty of CA hinges is it is really not much more trouble then the original install, to cut through them and start over with new hinges, moved an inch or so away from where the original hinges were installed. Your torque rod pivot axis should be on the same centerline as the hinge's pivot point. If this isn't the case, they should have been let in to the framework to allow this to be.

My opinion on the shape of the trailing edges and leading edge of the control surfaces where they meet is as follows. I make the T.E. flat, no bevel or rounding. The flatness should be perpendicular to the centerline of the airfoil, or what is called the cord of the airfoil. I bevel the L.E. of the control surfaces. A bevel is V-shaped, not round. The shape of the bevel should allow for the maximum the control surface will be deflected, at maximum throw. The control surfaces should be as tight as you can make them, without friction occurring between the two.

It is possible to seal the hinge gap on the model as you have it right now and you will not need to do any surgery at all. Take a length of covering material, the same length as the gap between the two surfaces and 3/4ths to 1 inch wide. Crease this piece down the middle, making this piece the length of the control surface gap and folded over, it will be one half of the 3/4th or 1 inch width you made this piece. Lay the crease in the gap and iron this piece to one of the surfaces, then the other. You might be able to do the same thing with Scotch tape. Just make sure the crease is all the way down to the centerline of the hinge axis.