"then maybe a continuous strip of Tyvek would be the way to go? "


I've been using tyvek for hinges on most of my foamies for the past 1 to 2 years and none of them have ever broken at the hinge line. (everywhere else though [X(] ) Awesome stuff and free....usually, I use Post Office Priority mail envelopes and cut 3/4" strips. I slit the beveled edges of the control surface and slide the Tyvek into place for a continuous hinge. Add some thin CA on both sides and it actually reinforces the edges and well as being a continuous hinge. When dry, I flex the hinge a couple of times and its good to go.

It would be easy to laminate a piece of Tyvek between two 1/16 pieces using med CA. Try this out and see if you like it.