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I countersunk stainless steel tinnerman washers into all my trailing edges
- flaps, ailerons, and elevators.

I found that on all trailing edges, the fiberglass had to be built up
somewhat to fair in with the control surface. Therefore it was NOT
necessary to cut into the original fiberglass structure.

I used a 9/16" counterbore with the appropriate sized pilot to do the job,
then bonded the tinnerman with Hysol as you suggested. I used polyester
glazing compound to fill in any steps or gaps in the finished product.

Ed: Just go on over to my hangar some Saturday morning and look if you
want. Clarence will let you in.

LML homepage:   http://www.olsusa.com/Users/Mkaye/maillist.html