Got the wider hinge material in from Aircraft Spruce – quick, easy and not too expensive. I re-fitted the right flap and checked edge distances. No problem!

Right flap fitted

One complete hinge has two leaves. That covers both flaps. For some unknown reason, I thought the FedEx triangular tube mailing box deserved a picture…so here you go.

New piano hinges for flaps

Plenty of margin on edge distance, but that forward (or lower, in this picture) edge of the hinge will have to be radiused to fit snugly inside the flap brace. Nothing that a few strokes with the file won’t fix.

New hinges on flaps