Dave,

The wing skins are 1/16" balsa. I used 1.4 ounce cloth inside and outside. So the hinge has two layers of 1.4 ounce. Then the three pieces of Kevlar. I cut the middle piece sort of in half, but Iwill probably just use a 1" piece from now on.

The carbon fiber tissue is 0.5 ounce and it is only on the part of the aileron outside of the hinge area. I extended it past the balsa so it would strengthen the area where only cloth and glue make up the sharp trailing edge. There is CF tissue on the top skin and the bottom skin. Iuse tissue because cloth is too thick, and laminate doesn't conform to the curves of the beveling of the balsa. Plus the random fibers strengthen the aileron in all directions. At the front of the aiileron there is a piece of 1/16" balsa (during the join). That's all the gap there is. That's a major reason I switched to 1/16"skins from 3/32". It was too hard to get the skins shaped properly. And the 1/16"skins are plenty strong with the 1.4 ounce on the inside.

Now I'm ready to put this plane in production and the initial kit price will be only $275 for the molded composite and $360 for a Ready To Paint with the tail jig mounted and engine mount / firewall installed.