RE: Skin hinge HELP!!
A word of caution on the skin hinges.....
I use them on occation on the Q-500 planes (they are somewhat standard equipment on composite birds anyway)
The skin hinges are great - they are strong, they provide an uninterupted airfoil top surface and a completely sealed control surface interface, but they are not suitable for anything where you will require any significant control throw.
On the Q-500 ailerons (1.3" wide) a throw of 1/4" up or down at the TE is considered huge (landing only configuration). Same goes for the elevators (maybe 3/8 max throw mixing full up and full rudder on the V-tail). We are talking 10-15deg MAXIMUM throws here.
From my experience (perhaps due to my selection of materials and process, Ive used both light kevelar and fiberglass) flexing the skin-hinge much more than that range, on a repeated basis, will cause a crack to form.
Just something to keep in mind.
Bob