RE: Hinge choice!
I too don't like ca hinges. I have used them on various planes with mixed results. I usually use the flat dubro hinges on 40-60 size planes and hinge points on anything bigger. Withthe flat ones I punched the holes bigger, to 1/8", six holes and I use 30 minute epoxy and gorrilla glue. Both glues are very strong. I did a test once where I glued the punched flat nylon pinned hinge into pine with 30 minute epoxy and I tried to rip the hinge out with pliers. The hinge separated, only the pin and the half of the hinge that was grabbed by the pliers went the other half stayed glued in the wood, and I REALLY pulled HARD with the pliers. The control surface would NEVER rip out. I have planes 3 years old done like this with no problems. I feel safe...