Another time honored method, is to drill or Dremel a 3/16" hole about 1/4" behind the 1/8" spar, (top and bottom) and after inserting the hinge, fill the area that the hinge lives in with BVM AeroPoxy. The AeroPoxy is thick enough to not run all over the iplace inside the surface, but it will connect the top and bottom skins to the hinge body. After the pucky turns to stone, sand it flush with the control surface, then fill and fair if/as required.


This technique is used on the Super Bandit ailerons,flaps, elevators and rudder to make a "bulletproof" hinge system.

Harley Condra
BVM REP
JetCat REP