Hinge Line Options

When you have finished preparing the holes, if they pass through the edges of the covering film, you could run around the periphery with a soldering iron (before full heat) to seal the film and prevent tears /separation. If you adopt Mikes method it will prevent surplus epoxy seeping under any overlap on the film

I glueone side at a time too - but I always install the moving surface (unglued) and work the hinge before the glue sets. This allows for fine alignment of the hinge centres, otherwise even a tiny misalignment ends up in a warping or sticky control surface.

Trust me to be different :silly: , I have always used 30 minute epoxy and done both sides at the same time, line the hinges up by eye to ensure they are square and the flex the surface to ensure you have full deflection. Have plenty of paper towels ready for cleaning up and a little bit of white spirit on a cloth cleans off any excess epoxy

Thanks to you all for your input. I'll use a combination of most of your suggestions and also follow Kevin's idea of a soldering iron tip to re-glue the film into the hole a little.

Resin W waterproof pva works well to, you welcome to come and try pulling them out of my 91" extra.......
pushing 80deg of ele throw and not pulled them out yet :evil:

Also dont need to worrie about "greasing" the pin, just roughen them up and glue them in!! when dry just "crack" the hing and it should free up!

I have had a go using this method on the fin as a test. The holes are 4mm and the pin heads are 5mm. I scored around the hole with a scalpel first. (Jon T) Then twisted by hand (or fingers) a 5.5mm drill bit in just a few millmetres. (Alan F) A quick insertion of a soldering iron round tip (in and out) (Kevin R) and then inserted the 4mm hinge. Perfect Pivot pin is just level with hinge line. Film covering looks good. So, only 18 other holes to do..... :whistle:

Thanks to all. I'll be following the Forum intensely for the next few months as I'll be unable to drive. Anyways, you won't miss that lunatic with a foamy MXS and a hangar full of virgin warbirds... :lol: