RE: Acceptable aileron hinge gap for a Trainer?
flynte,
You're one small step away from a very good hinging job.
You're using "hard" nylon hinges. Kewl.
Right now your gap is exactly as wide as the "hinge" part of the hinges. You got two different techniques that'll work.
It looks like the TE of the stab is square and the LE of the elevator is rounded. Those aren't the best profiles for the easiest built modeling zero gap hinge line but......... That's what you see a lot on "real" airplanes. But they have the hinge inlet into the elevator completely. No inletting into the stab at all. The hinges stick out there. Their idea is to put the CL of the hinges where the center of radius of the LE of the round elevator would be. The LE of the elevator then will rotate, but won't open or close the gap while rotating.
The easiest build for models.... Inlet half the width of the "hinge" part into the elevator and half into the stab and test the fit and freedom. It usually works out ok even with a rounded LE on the elevator. But it would have worked out really good had that LE been sharper and had lined up with the centerline of the hinges.
Hope this helps.