I am installing Robart hinges and have a question:

The instructions say to use a 1/8" drill bit, which corresponds to the diameter of the barbed portion of the hinge point. Looking at the hinge, as you get closer to the hinge part the cross section gradually becomes square and overall larger in size. This means that the first half of the hinge goes in the hole rather easily, but the second half requires a lot of force, and I am afraid if I force too much I will either split the balsa or squish the piece through the force of holding it tight as I push the hinge in place.

I am thinking of enlarging the first part of the hole to make it easier to put the hinge in place, is this the right procedure?

Robart has a "How To" on their website; http://www.robart.com/how_to/hinge_points.aspx

If you follow their directions everything will be just fine.

ppkk I use a small reamer mounted in my drill. I ream just 1/8 or so into both surfaces. Allows the square part to have room and gives a nice tight hinge line. Make sure not too tight so you bind the surfaces. If the wood is soft I have also just pushed the hinge into the wood and let the square part make it's own area. I use Zap hinge glue and wet a Qtip with water and wet the area before added the glue, allows the glue better penetration. Good luck.

I take a 1/4" dowel and wrap fine sandpaper around it, then I sand up and down over the 1/8" hole to allow the hinge to seat into the TE of the wing and the LE on the aileron, rudder and elevator. Also, this allows the gap to get closer together. Hope this helps

Look at #5 of the Robart instruction. They use a 1/4" drill and pull it back and forth, I use the dowel with the sandpaper.

That's what I do. I forget what size drill bit, maybe 1/32" or 3/64" larger and about 3/16" deep. Still need to push a bit to get it in all the way so it's more than tight enough.

Does anyone have suggestions on adding the glue or epoxy... I have been holding off on this as I'm worried I'll muck it up having never done before. I'm concerned about knowing the amount of glue I will have in the hole is enough. Do you want to see a small amount ooze out? Also.. what is special about ZAP "hinge" glue?

Thanks all, appreciate the tips.