Agreed. However, it's morning here and I'm procrastinating about a brochure that I've designed and had approved, but now have to do the not-fun part of stamping out copies with differing text. Hoist one for me, will 'ya? :gig:
What I meant was that it's easy to make something like designing aileron hinges too complicated. Piano hinges have quite obviously worked just fine in many an airplane, so in similar applications and with the same reasonable amount of design effort you'd use for anything else in the airplane, they ought to work fine elsewhere. As I mentioned, my dad's old Aeronca had aileron hinges that were just a couple of bolts in single shear. Optimum design? Hardly. But the airplane was forty-something years old when we got it, and the ailerons worked just fine.
I think I'm following you. And I highlighted 'mold warp', thinking "mold warp as in thermal expansion, for example?" I see what you're getting at, but I don't think I'm quite convinced. I agree that setting it all up and fixing it before infusion is better than the alternative I mentioned earlier, but the infusion process is going to put a lot of forces through the system, and I can see things moving around, if only a tiny little bit. Which might be enough to require scrapping the part. The great big expensive part.
I guess I'm a great skeptic about processes that require near-perfection in execution, particularly as applied to the shop of an amateur constructor like you or I. I'd much rather attach the piano hinge to the aft spar with small bolts, and then oversize the bolt holes in the hinge slightly, allowing them to be adjusted to perfection during assembly. YMMV, of course.
