Bob,
<<he has considerable wear on the right aileron and right elevator hinges, >>

I would suggest Marc check the mass balance of the ailerons in addition to fixing the hinge play given the report of actual flutter.  Also, assuming the aileron balance weight is installed on the 235 similarly to the 320/360, the installation of the may need some stiffening with gussets.

Regarding the play in the hinge itself.  I have used three types of hinges:   Regular MS hinge+MS pin, MS hinge with the Teflon sleeved pin, and reamed MS hinge with an oversized hinge pin.   The play built into the MS hinge and MS pin combination is destined to get worse with time.  The Teflon sleeved hinge will prevent wear of the metal parts, but does not eliminate the play.  Over time, the play will grow if high loads are applied to the hinge.  The reamed hinge + oversized pin has the lowest play of anything I have come across to date and is proving, thus far, to be the longest lasting, even under high loads.
The following links shows a video of the play in various hinge/pin combinations

http://www.n91cz.com/HingePlay/Hinge_Play_Test-low_res.WMV  2.37 Mb
http://www.n91cz.com/HingePlay/Hinge_Play_Test.WMV  13.22Mb

Chris Zavatson
N91CZ
360 std
www.N91CZ.com