Per,

The method I use for skinned hinges is a little different. Instead of the big through hole, I bevel the bottom surface similar to using monokote hinges. The gap is needed on the bottom for the surface to move (approx 1/8" - 4 mm). The top gap is considerably smaller approx 1/32" - 1 mm. I use kevlar for my hinge material (caution: don't try to sand it or else you get the fuzzies). To do all of this I shape my balsa tail with the elevators attached as one piece. Then I use an Xacto knife to cut the "V" shape into the hinge line. My first cut is perpendicular to surface and the second is on an angle (use a straight edge). This is all done from the bottom side. After I remove the balsa piece just cut out, I turn the stab over and make a second cut just behind the first to widen the gap along the top surface. I do not cut the ends of the surface until after it is bagged.

My two cents,

Dan

Lastly, I do not put the torque rods that far into the surface. I only extend past the edge of the elevator approx 1.25". Does anyone else put their torque rods that far into the elevator? (it looks like the rod is approx 4 inches long)