Hello Ian!
On 17 Aug 97, Ian Macaulay wrote to Roger Marshall:
 IM> I'm doing a repair and normally i bury the joint at the hinge points. 
This
 IM> time round that area is unaccessable because tail assembly is intact and 
I
 IM> have only had to rebuild the rudder.  The hinges are pined and inplace.
I normally do the same for strip ailerons and elevators, using one strip of 
Monokote, but if the surface is illegular (like the rudder on my Extra-300) 
I'll use one piece for each side.  Careful iron work will hide the joint 
pretty well, and it won't separate (unless it's Ultrakote).
For your repair, it sounds like the rudder is still attached.  What you might 
try is to seal the air gap at the hinge point.  Use my two-piece method, but 
before ironing the covering down to the hinge area, flex the rudder all the 
way in the opposite direction... iron the covering down, and carefully trim 
it flush with the trailing edge of the fin, then repeat for the other side:
       | |
       | |
       | |
       | |    ___ SECOND: Cut covering flush with this horizontal edge.
       |_| __/
       /^\   FIRST: Bend rudder that way and iron covering on this side
       | |   <=======================
       | |
       | |     Repeat for the other side.
       | |
        V
C-ya! Rich
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