Following is an e-mail I received from Ray Goree about an aileron problem. I hope Ray doesn't mind me posting my reply to the net so that others may benifit from my mistake also.
Larry Flesner +++++++++++++++++++++++++++ Larry, Dan Heath suggested that I call you about my aileron problem. I am working on my first one. After completing the first on, I put it on the wing, and with the inboard edge lined up with the wing, the outboard was 1/2" low. I think this was because I did not have the spar perfectly flat. I have finished removing the old spar and am shaping the new spar. I understand the spar should be flat and straight. Right now , one end of the spar is approx. 3/16" low. I am thinking of building that up to make the surface flat all the way. Another option would be to epoxy the parts together, let them cure until real "tacky",then place it on the wing,clamp both ends in place, and let it finish curing. I will be checking the aileron on the wing this afternoon. The last time I did this, it "lined"up. Thanks, Larry +++++++++++++++++++++++++++++++++ Ray, I think Dan sent you to the right place. Sounds like you made the same mistake I did. After cutting out the aileron I installed the aileron spar on the work table. I forgot about the 3 degree washout of the wing (twist) so my tips did not line up at the inboard and outboard end. My fix was to install the aileron and clamp the inboard end to the wing trail edge. I then cut the aileron skin just behind the aileron spar on the top side with a dremel tool from the outboard end and approx 2/3rds the length of the aileron. I then clamped the trail edge of the aileron at the outboard end to the wing trail edge. This will leave a bit of a gap at the cut line. Fill with a small amount of flox/epoxy mix to hold the proper twist in the aileron and remove the aileron from the wing and probably the hinge from the aileron. I used "deck cloth", the light weight glass as it conforms to the edge much better, to repair the cut. I used four or five layers and staggered the edges a bit. After finishing you won't be able to see the repair. Make sure the hinge is attached and holding the aileron in position when you do the cut, realignment, and flox patch. This should have your tips perfectly aligned when finished. Good luck. Larry Flesner
