I bought some hinge material from a local metal supplier

But the aluminum angle does not have a radius on the inside corner of the angle.

On the stabilizer hinge plans it calls for a radius on the angle

The plans call for .093 but the nearest size is .125...I don't thinks a problem substitute the next size up

In the rudder part of the plans it calls for the same size angle but with no radius.

I looked on aircraft spruce site but there is no pictures of the angle...

Does the 3/4 x3/4 angle you guys have. Have a radius on the inside of the angle

Your thoughts on the matter

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The angle you have is incorrect. I am speaking to the 701, but I am relativly certain the same is true for the 640. The .093 the plans call for was not redilly available except from Zenith. .125 is an acceptible substitute. the problem you have I beleive is that the angle you have is not 6061-T6 alloy which is structural which is what you want. you have angle which is considered decorative where appearance is more important than strength and is probably 6063 alloy which is unacceptable for our application. any aluminum used in your aircraft should be clearly marked from the mill as to it's composition. I could be wrong, but I seem to remember reading that in Canada it was necessaty for the markings to remain thru inspection for it to pass?? Dan.

Thanks for the info, I only spent a few dollars but it's a lesson learned.

The Zenith construction standards book calls for 6061 T6 for extrusions, I`m sure if Id asked for that I would have gotten the right stuff. I appreciate all the tips Dan, I watched your rudder tip video and many others you have up...Great Stuff!

You could buy 1 X 1 X 1/8 from Spruce and cut it down to 3/4. $1.80/ft from Spruce.

If you don't mind sharing, I am curious why you would not go to Zenith?

They sell raw materials 

Yeah I know, thanks.

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