RE: Cutting grooves for hinges
Thank-you all for advice. I ordered and received the slot cutting equipment. While I was waiting for it to arrive I proceeded re-installing hinges. Hopefully the pictures below will help explain what I did.
First, I cut the old hinges out of the control surfaces. In doing so, I made the holes pretty big (relatively speaking of course). But far too big for friction to hold the hinges in place. I needed to devise a way to hold all the hinges in place while epoxy filled the holes and cured.
I took pictures of my work on the elevator.
1. I marked the position of the hinge.
2. Then I transfered that mark to a length of angle aluminum. It has to be angle stock because it is by nature straight.
3. I clamped the hinges onto the angle aluminum, I made sure both "flaps" of the hinges sat flush on the angle. With four hinges needed for the elevator, this assured all hinges pivoted along the same line.
4. I clamed the aluminum to my workbench. You can see in the pictures I test fitted the elevator to make sure everything was set.
5. I mixed up some 15 minute epoxy, and put the hinges in place on the elevator. And let it cure for a couple hours.
6. Then I epoxied the elevator/hinge assembly in place.
The end result, spectacular! Night and day difference. As I type this, I've just finished the aeleron. Once this is cured, I can finally install the aeleron servo, and finish radio installation.. I... gorsh I can hardly believe it.. I'm only a few hours of work from being flight ready!!!