RE: Flap servo binding...
One more thing:
At the end of the deflection, where the air force against the little motor in the servo is maximum, the linkage should look somehow like the attached schematic.
Note that the pushrod should be perpendicular to the line formed by the hole of the horn and the hinge of the flap in order to have maximum leverage.
For the same reason, the servo arm should be as far from 90 degrees as possible.