Some more forward progress tonight. First up, I got the right wing panel/aileron all hinged up. I will get it sealed tomorrow.
For the control horns, you always want to make sure you cut away the covering from below this little spreader plate. I cut out the slots for the control horns, then dry fit them with the spreader plate in place and then cut around the plate. Then, remove the horns and simply peel back the covering.
Make sure you sand up both sides of the control horns as well as the bottom of the spreader plate so they get a good solid bond. Dry fit them in place again and double check to make sure the control horn holes are seated right over the hinge line.
If all fits good then get yourself some 30 minute epoxy, mix it up real good and stuff, then coat the control horns, plate, and elevator thoroughly and slide it all in place. Wipe away the excess epoxy with some rubbing alcohol and paper towels for a cleaner(ish) fit. I also like to fit the control linkage in place while the epoxy cures to ensure that they glue in place straight. I took advantage of this curing time to cut out the covering over the servo arm slot and get my servo prepared for mounting.
You will need a LONG screwdriver for this since the servo sits WAY inside of the pocket (you can use a small and narrow screwdriver like I did, but it's easier with a larger handle). I always test fit the servo and get it all screwed in place, then remove the screws and servo so I can saturate the screw holes with thin CA to make them nice and solid, give the screw something hard to bite into.
Once the servo was in place I slipped the SWB arm on, tightened up the locking screw and the servo horn screw (as you can see, I used a button head hex screw that was included with the servo), and got it all centered up on my transmitter. Since I am using the Maxima 6 receiver which has a 4096 resolution, the servo movement was barely noticeable (even with a long arm)
A testament to how smooth these servos really are!
The last step to complete the elevator/stab half was to fit the supplied turnbuckle to the the servo arm and control horn. I swapped out the supplied hardware with 4-40 screws and nuts since the servo arm is tapped for 4-40. Better to have all of the same hardware on everything so you don't have to go looking for different tools when it comes time to work on it.
As I suspected, the 9485 servo is EXTREMELY linear, responsive, and precise with zero slop whatsoever. It moves exactly when the stick on my transmitter moves, thanks in part to the Maxima's 7ms latency and 4096 resolution. This should be a very fun and precise airplane to fly
As I stated before, I oped to go with 1.5" arms rather than 2" arms. I seem to be able to max out the control surface just fine, but if I wind up not liking the 1.5" arms I can always swap them for 2" arms down the road. I'll of course be posting a flight log.
That's all for tonight. I didn't realize how late it was getting, otherwise I'd have continued on. Will be fitting more servos tomorrow.
I just had to get an idea of the flight characteristics of this plane. Your thread enticed me so much, I had to do some investigating. Usually when I get to that stage, it's a pretty much a done deal. 
Besides, it would be an awesome beater plane. Especially since I sold "Lil Purp".
