Today, I started fabricating the trim tab hinge from an 18" piano hinge (AN257-P2).  I got the trim tab side of the hinge drilled, deburred, and cleco'd to the trim tab.  Looked really GOOD.

I then re-installed the hinge pin to line up the left elevator side of the hinge.  I drilled the first couple of holes by folding over the hinge and drilling the hole.  This aligned the rivet lines between the trim tab and the left elevator.  I then was able to cleco the hinge to the elevator rear spar.

I then had a brain fart and decided that the left elevator side of the hinge was required to be countersunk in order to accept the flush rivets that would be set attaching it to the left elevator.  AFTER drilling all of the holes, I remembered that the top side of the left elevator rear spar was countersunk, and therefore, required no countersinking of the trim tab hinge (NOTE TO SELF:  write Van's a check for another $3 for a new hinge).

If that wasn't my only problem, the holes in the trim tab hinge (elevator side) got elongated / distorted from the countersinking (probably why Van's doesn't have you do this).

The extra hole came from when I folded the hinge over to drill the holes in the hinges such that they lined up between the elevator and trim tab sides.  This worked with the exception of the hole to the inside (or right side) of the elevator hinge.  The edge of the elevator is angled therefore the rivet line is not straight forward to aft, but angled to line up with the edge of the elevator.

Now I have to wait for a new hinge.