HighWing and WarEagle, thanks for the very informative posts. You both have done some tremendous work on your planes. You both mentioned filler between the cowl and hinge to fill a gap and this reminds me of another concern. Does the hinge need to be kept flat along one axis or the other? Obviously if the two sides of the hinge are flat then the hinge will rotate smoothly. When both sides are lined up, the hinge is completely open or at 180 degrees, it seems that you can put a pretty good bend in it like WarEagle did on the boot cowl in one of the pictures. The way my cowl pieces are I envision that the hinge will be "closed" to about 160-170 degrees and it will then go around a slight curve, probably 20 degrees over a 2.5-3' distance. Is this going to work or will a wedge need to be made so that the hinge sides are aligned with one another?