Today was the big day of bending an elevator or two. Went to the big box store last night to get a couple 2x8's to make the brake. Got lucky and found two straight boards in short order. Had the store cut them to size so I wouldn't have to switch from metal shop to wood shop. Shop around for hinges. I was looking at 2 to 3 dollars per hinge, but found some on sale for 98 cents.
Now for the moment of truth. I used some scrap stiffener material and riveted it to my scrap elevator skin. Internet research shows you want the trailing edge of the elevator right up to the hinge edge of the brake. Standing on the floor I was able to bend it a ways, but I had to get on a stool to finish the job (The tan material on the brake is that rubbery drawer liner or carpet anti-slip sheet. Keeps the skin from moving on the brake. Many uses for the stuff). Pic 2 shows the test skin. It is still a little curved becaused it is not fully stiffened.
After researching I agree that countersinking the nutplate holes on the trim tab reinforcement plate is the way to go. The problem is the material is too thin for the pilot hole of the countersink to stay centered. Others have clamped on extra aluminum sheet for this. I realized I could just drill it to the table top again. The piece has stiffening flanges on two sides, so I just put the piece on the corner of the table with the flanges over the edges and match drilled the nutplate holes. Then I countersunk the holes with the table top providing the pilot hole. Turned out perfect.
