What is the best way to align and cut CA hinges by hand.

Rotary paper trimmers such as these would be perfect for cutting your own CA hinges, perfectly straight all the time.
http://www.abcoffice.com/carl95.htm
http://www.abcoffice.com/cut350.htm

Cut the hinge material with a good pair of scissors. Cut the slot with a #11 hobby knife. Just make sure you mark your slots in the center. Cut the slots slightly wider than the hinge material to allow for any minor misalignments, and to make them easier to install.

Brad

I use the same method as Bread. I mark the position in the center of all locations then I use a number 11 Exacto knife blade and make multiple cuts, going deeper with each pass. Make the cut a little longer then the hinge you are using and then you will have room to work the hinge into place. Once in place lay a bead of thin CA on both sides and let it dry, WHALA your done!!
Nevin
G17Staggerwing

CA Hinge Installation

There are several rules to follow for an easy, correct CA hinge installation. These rules are good for hinges from different manufacturers, including Great Planes and Radio South. I’ve used them on many planes from pylon racers to Unlimited class Fun Fly planes to even a giant scale Stinger (the 1/4 scale size hinges). I have never seen an in-flight failure using this procedure.

I have seen only two in-flight hinge failures. One failure was from catastrophic flutter, which also destroyed the wing panel. The other was due to doubled hinges and the use of thick CA.

Here we go:

Use a #11 blade to cut the slots.
Cut only once per side/per hinge.
Use only thin CA.
Do not double the hinges.
Do not use “kicker�.
Install after covering.

1. Slot the wood pieces, install the hinges, and mount the control surface. Gently push the pieces together.
2. Flex the control surface both ways for the maximum amount of travel you expect to use. This will automatically create the proper hinge line gap.
3. Slowly drop 2-3 drops of CA on each hinge at the hinge line on one side only. If any CA puddles in the hinge line, blot it with a paper towel.
4. When that is dry, apply 2-3 drops of CA to the other side of each hinge.
5. When both sides are dry, flex the control surface both ways.

That’s it! The wood will pull out before the hinge will let go. The surface will tend to stay centered and will not flop around. Both will help prevent flutter.

Dr.1

I would also add that you can put a pin in the middle of the hinge to keep it centered between both surfaces. I've had them move when trying to assemble the surfaces. If the pin is keeping the hinge gap too wide for you you can remove it before you glue. then just push the gap closed, flex the surface, and glue.

Hi fellows: This thread is doing well for installing hinges, but I would suggest leaving out the #11 blade and substitute the Great Planes electric slotting tool. While I understand the great skills everyone has, it is just a lot safer to keep the blade from cutting a body part. The other positive side of this electric slot cutter is that the slot will be cut centered and straight in the wood. There is also an alignment tool that works well to center the cutting blades.


Rich S.

SORRY, I thought he was asking how to cut single CA hinges from a sheet of CA material

You against giving a little well-practiced help, tigerdude426? Fine, to answer his question as you see it...I use a straightedge and a #11 blade to cut the size of CA hinge I need.

Dr.1

I use a bit of a variation when installing ca hinges. First, I put a crayola line across the hinges at the mid point. Both top and bottom. Then I insert the hinges up to that line in the fixed half of the control surface. Flex the hinges past the point that the servos will push them and glue with a couple drops of thin ca on each hinge. Fifteen seconds or so later, flex the hinges in the opposite direction and glue that side of the hinges. The crayon line is still visible. Now slide the control surface onto the hinges. Flex the surface one way and glue. Then flex the control surface the other direction and glue. The crayola line is still visible when the surface is thrown one way or the other. If the same color crayon is used as the covering is, it looks kinda neat when the control surface is flexed. As an added attraction, the ca will allegedly not pass the crayon line in either direction. Don't know if that works in controlling the flow of the ca or not but the end result looks kinda nice and it can't harm anything even if it doesn't work. And if it does work in ensures you a nice flexible point at the mid point of each hinge.