Went to Copperstate EAA Regional event. Saw the 3 Sonex and 1 Waiex in attendance. Checked out how they worked out the flap to aileron gap, since that's what I was working on at the time. They all had about 1/4" between the two, but trailing edge alignment seems to be tricky. One of them shifted the aileron hinge aft about 1/8" to line them up better. Looking at other types of airplanes, some have 5/8" - 3/4" between the flap and aileron (of course the composite speedsters have maybe 1/16", if you can see any light at all between them). Several airplane types run three short sections of the piano hinge, each maybe 3-4" long to attach ailerons, so the Sonex continuous hinge is structural overkill. This being so, shifting the hinge aft a little won't hurt anything. After much deliberation, I'm going to leave what I've got on the LH wing and see how the RH wing turns out. If it's better, then I'll redrill the LH hinge to match it.
