RE: In flight CA hinge failure...
Well, like Deadeye, I too have never had a CA hinge fail. However, with the exception of a few large-scale planes, I have used CA hinges exclusively since the late 80's - that's almost 20 years.
I have even used them on some large-scale gassers.
Two of the planes that I used them in back in the 80's are still flying.
Also keep in mind that I do product reviews for RCU. That means that while most guys build one or two planes a year, I build about one per month - and I have NEVER had a failure.
Are there a lot of "Secrets" to getting them right? No.
I wrote a "How To" about putting in CA hinges that many of you may have read where I say to "Remove the covering around the hinge slot, and drill a wicking hole" - The truth is, I don't even do THAT! I put them in, bend the control surface MORE THAN IT WILL MOVE IN FLIGHT, and add 4 - 5 drops of CA (to each side)
I have used every type of hinge on the market (And some that AREN'T on the market) and NOTHING is easier.
As far as CA cracking the material of your pants, yep, I've got several articles of clothing with one of those dredded CA cracks, but this is FABRIC that the CA wicks into and hardens. CA does not wick into the plastic which stays flexible (AS LONG AS YOU HAVE GIVEN IT ROOM TO FLEX)
THE single most critical thing about installing CA hinges is to hold the control surface in a deflected postion (Once again, more than it will move in flight) as you are applying the glue. If you do that, you should never have a problem.