I am looking for better and different ways of installing large flat type(i.e. 1/4 scale Klett) hinges. The reason I ask is because I had all the hinges pull out of my rudder but this was after the Extra had snapped on me during a deadstick. I have been installing hinges for some 25 years and this was the 1st. time I have had this happen.
I always wipe the hinges with acetone to remove any mold release and I use vasiline to cover the pivot part of the hinge...then I mix 30 min. epoxy and a small piece of brass to push epoxy in the hinge slots. I let that sit over night and then do the same for final installation.
Is there beter and faster ways of hinging that I am missing???

BTW...the Extra in question is the one in the avatar...it flys great but it sure did damage it when it snapped on me and it did not hit very hard but this plane is built to fly...not crash. Seems like it has been one of those summers when all I do is crash everything.

..........You're doing everything wright. I might add that pinning the hinges would add more security to both the plane and your piece of mind.

Sometimes the epoxy doesn't seem to stick. I rough the surfaces of the hinge with my sanding bar - just go over a couple of times - and this seems to help with the bonding.

I also pull at all my surfaces after every thing has set, I would rather it come off in my hand than 100' up.

I like to use a little microballoon in my epoxy for hinges. I also use two hour epoxy. I set the surfaces so that I can just allow the epoxy to run into the hole after I lay it into the little trough I cut for the pinned portion of the hinge. I go from hinge slot to hinge slot adding a little bit as it soaks in. Then I place the hinges in and attach the surfaces and lay the piece flat so that the epoxy niether runs into the wing or out of the slots.

The microballon seems to allow the epoxy to get a better grip on the imperfections of the hinge. I have never lost a hinge this way.

Mark

I always use RC-56 in balsa wings because it sticks well to plastic and wood, and the wood swells around the barbs.

Does anyone know if Rc-56 sticks to foam? I heard it does. I haven't tested it yet though.

Mark