Steve,
You may find these useful for CLPA:
http://www.robart.com/Hinge.aspxI have been using them for many years. They are much easier to install than the flat hinges, they work smoothly, and are very strong. Used with their drill guide, perfect alignment is easily achieved. When you epoxy them into one side, you just bend them down to 90 degrees with the surface while they dry then insert into the other part (EL, AL etc.). After years of abuse in my planes I have not had one fail or pull out.
RE: getting a close slot.
Reasonably close is more than adequate if you seal the gap on the bottom with tape.
http://www.hobby-lobby.com/spoilers.htm#GapSealing the gap will help in many ways. The only better way I know of is molding a convex LE perfectly into a concave TE. This seems to be a lot of work, but I have seen it on some outstanding Sailplanes. I'm sure this type of LE, TE is available commercially somewhere in Europe, but I don't know where?
I hope we hear from some CLPA "Pro Stunt" experts on this. I would be interested to see what they use?