Hi- I am settin up the surface deflection on the Flip 3D - this is my first 3D bird- I'm using 9202's, 1.25 servo horn, 1" control horn, the pushrod is on the second outer on the servo and the same on the cont.horn - When I move the sticks (elev. & Rudd) the surfaces "Jump" and thewhole fuselage moves kinda wierd - set -50 % expo also - is this normal when you get into these large throws ? seems like too large of movement to be smooth - whats the fix??

Sounds like the set-up is binding somewhere and the end of the travel is too much.

Any pics?

No Pics - No Camera, I don't think it's binding though - this happens all through the servo travel range - like the servo is pushing the surface too fast - ??

Also it dosent do it on low rates - (-50%) nice and smooth with less throw

What kind of hinges?

3/4 x 1" CA

I am using a 1300 ma 6volt battery - would the servo's be jumpy on 6v??

Yes, they can be.
What is the voltage reading on the batteries after a charge?
(I assume you are not using a regulator.)

Not sure, I just used my peak charger, will test it tonite when I get home, No regulator. At what point do they start being jumpy? What voltage does the regulator put out? I wanted the better output/speed of 6v - should I just run a 4.8 pack?

Try a 4.8V pack just to see if the jumpiness goes away. If it doesnt, I'd look at the linkages, surfaces, connectors, hinges again.

Regulators......
I run Powerflite Li-Ions in my 33% Cap and they are 7.2V Batts
The regulators take them down to 5.7V
I usually see close to 8V after a charge.

I would also add that you should check your expo settings.
Make sure that if your using a Futaba radio that your expo% is a negative number EX: -65% . I did this on my Kangke by mistake and set the expo to +75% on 3d rates and almost lost the plane.
Negative numbers on Futaba radios makes the controls softer around center. For JR radios it's the opposite
Also you should start with expo setting of around 65-75 % on the flip. You will be surprised at how much expo you need.

Yeah, I've got -50% in there now, was wondering if that was enough..... if you did'nt have any -expo would the surface be jumpy just due to the amount of throw per degree due to the long horns/arms?

Definitely, For 3d rates you loose alot of the servos resolution due to the amount of surface deflection (roughly 40 to 50 degrees)
So expo helps keep the speed down around center even in low rates. This is why digital servos feel smoother, they have much higher resolution to begin with (more steps per degree of movement).

Remember to switch out of 3d rates once you finished the maneuver. I use Triple rates on a 3-way switch.