"Nowadays with oil free systems, I'm considering something like cloth layered between two sheets of wood. You would build the wing trailing edge and the flap leading edge together."
Sort of like the sealed hinge strips that Ralph Cooney, Foremost products, had available some years ago. He used Tyvek sheets, the kind from mailing envelopes, sandwiched between balsa sheets. I believe that the adhesive was contact cement. He made up whole sheets laminated that way and then cut into individual strips complete with v-notches using a special multiple cutter saw blade that he made up. I have some in my possession but have never actually used any. I checked his web site and they are not listed there so he must have dropped the product idea.
Jack