I purposely left the aileron bushing mounts long. The idea is that I want to “machine” them to the proper size and if you cut too much....you have to start over. So, I began to install the ailerons and then I measured the actual required length and compared that with the plans. The plans vs the actual were nearly bang on, slight adjustment were needed and only by a few thousandths.
So I went to work with the drill press and fine sandpaper (400 grit, 600 grit and then 800 grit).
Once I was happy with the fit. I started to install the ailerons. It's not the easiest process to get them installed as the small washers have to be installed in fairly tight locations. I found an easy way to install multiple washers was to wrap them in electrical tape and then using a popsicle stick to slip them into position, allowing the bolt to be slid in.
I had given some though how to position and secure the aileron for alignment and storage. I decided to use aluminum flatbar as I felt this the best and most secure (as well as precise) method. I marked all the necessary holes to align as per the plans and drilled the holes on the press.
I installed them on the wing to check fit and to confirm the location of the ailerons. This would allow me to place the holding "pin" in the exact proper location.
I made holding "pins" using really long, small diameter bolts. These will sit inside the aileron on the trailing edge and help secure the aileron.
Once installed, it help the ailerons in perfect alignment and also allowed for me to install and adjust the aileron control rods.
