More progress and new pictures..

Today I hinged the rudder..

First thing I did was mark the hinge points from the plans onto a 1/4x1/4 hardwood stick cut to the length of the rudder hinge line

Then I drilled 1/8" holes in the stick on the drill press.
Now I have a drilling jig for the robart hinges.
I also added a little 1/16 sheet scrap to allow a small gap between the stab and rudder. The covering will close this up a little.

The jig gets taped to the rudder (pic 1)
then drill the holes (pics 2)
In pic 3 you can see we have a nice set of perfectly aligned holes.

In Pic 4 we follow the same process on the stab. (note the 1/16" spacer)

Pic 5 I've sanded notches into the rudder for the hinges.. you want them flush with the TE when folded over 90 degrees.

Pic 6 shows the Rudder installed but we still need to cut the bevels.

Pic 7 shows the finished rudder.. it has almost 45 degrees movement and a nice tight hinge line.