A couple of weeks ago I began working on the left aileron. I started by carefully ripping down a scrap of lumber to create a 120 degree guide for the Fein tool while cutting the aileron from the tip wing skin.
Pictured here is the top wing skin after cutting. This part of the operation was done correctly. Unfortunately cutting the aileron from the bottom skin didn't go as well. I made a stupid mistake when transferring the measurements from the plans to the wing and then cut too much from the wing. I was really upset with myself for doing that, but after some calm planning I realized that the fix was not going to be a big deal at all. I glassed the aileron back onto the wing (underside only), let it cure and re-cut the aileron correctly, all was good in the universe again. Unfortunately I did not take the time to take photos of this process.
Pictured here is the left aileron with the 7/16" steel rod counter weight bonded in place.
Pictured here is the aft wing rib that is laid up with 3 plies BID glass into the area the aileron was removed.
Aileron control hardware should be arriving by UPS tomorrow. I hope to have this chapter wrapped up by then end of this month or early March.
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