RE: Control horn problems on 73" Yak.
Hi There,
I would move the one doesn't line up with Ail hinge line further back so it does line up. If you can make the slot a little bigger and move it, it would be fine. I would try moving it, shouldn't be hard to do, this way you will be compensating for the 1/8" difference. You can fill the gap with glue, epoxy. This won't cause you any problems. If you just lengthen it with xacto knife, you will be just fine.
Let me know if I could help you any further,
Reza
Quique's Aircraft Support