I'm hinging a 3D wing, It has a 3/4" flat TE on the wing it's self, and the aileron had a 45 degree angle, tri stock glued to a flat LE. I'll be ablt to cut into the LE of a aileron a little bit, but ideally, the hinge pin will be along the sharp LE of the aileron. I'll taper, or actually step cut the taper with jewelers burs. I just did the rudder and it is going to workd out OK. However, on that surface, the plans called for a round edge on both the TE of the vertical stab and the LE of the rudder. That required quite a gap to get full movement and I'm trying to get around this gap with the re-hinge. I had to cut shape the LE of the rudder some for full movement. It is going to work OK. THe elevator will be that same story. Sure would have been nice to have been able to remove the old hinge tabs, but I just cut the lugs off and ground the tab down below the balsa surface. THis allowed some shapping of the LE, but will not let me get a sharp edge.

Assuming tihis goes OK, I'm going to re-hinge the ailerons on my Supper Areromater. Then I can get back to some real building again.

Thanks for all the help guys. Even if an answer didn't really address my situation, I would learn from it.

Don