Based on the past discussions, I have decided to use CA hinges rather than the plastic hinges with epoxy install on a couple of H9 ARFs.
My question is: What is the best way to get past the large pre-cut slots that have already been cut in the factory? My thoughts are that the CA hinges placed in the same [large] slots will be very loose fitting and will not bond correctly.

I would cut new slots, except that it will be impossible to fit a new slot close the the ends of the control services. [As their are already the large slots located in these important locations.]

Let me know what you think.

You might be asking for trouble if the slots are already cut too sloppy for the thinner hinges. Having said that, I think I would try cutting a piece of 1/64th ply and gluing it into the slot... being careful to get the glue on one side only. If that tightens things up, then I would proceed with the CA hinges and then pin them with a toothpick if still a bit unsure of the tightness of the fit.

Ernie

Thanks alot, very helpful.

It confirms my hunch.

De-sky

De-sky,
are you talking about the width of the cut being too big and the ca hinge sliding sideways? If so this will hurt nothing.

Now if the heigth of the slot is off and the hinge just falls in and out you are going to have to do something to fill the gap.

Its a personnal thing but I do not use the H9 hinges that get sent out with the arf's. I normally use the Great Planes material that comes in sheets and cut them 1" x 1" or I use the ProSouth blue hinge material, if I can find some that does not luck cut too crooked.

If the gap is just too big in width then when you ca the hinge in place you ca the wood back together. The gap should be the heigth of an xacto blade cut.

Ed M.