I had a little scare this morning when I went to put the hinge pin through the flap hinge for mounting. I had introduced a very slight bow into the hinge as I attached it to the trailing edge of the wing, so the hinge pin went in a little tighter than I wanted. Since I'd split the hinge to attach it, there was a little flex in it that allowed the bow to develop. Luckily, I had attached it with #40 pilot holes, and there was enough distance to straighten it out using the difference between a #30 and a #40 bit. In other words, the #30 bit was big enough to allow for the #40 hole being slightly off-center, and swallowed up the hole in the process of making it bigger. Wow - that's hard to explain. The lesson here - attach hinged control surface hinges with the control surface attached so that you know the fit is good before you try to put in the pin. Duh.
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