Updrilled upper skin surface rivet holes; left the cleoc's out after drilling. Placed the aileron upside down on .025 and .032 stacked angle stock to obtain .057" spacing for the hinge placement. Drilled and cleco'd hinge. Up-drilled hinge and vertical surface holes to #30. Up-drilled remainder of aileron holes to #30.
Disassembled all parts. Deburred. Spent a decent amount of time finalizing fit of tip rib to the skin. This entailed trimming the skin edge to match the tip rib - about 1/8" in two places. Filed edges smooth. Not 100% perfect, but given some of the reports from other builders, I'm happy with it. If you note in pic 1 below, the upper right corner in the picture shows a slight buldging-out of the skin. Un-cleco'd or un-riveted, this created about a 1/32" gap at that corner of the tip. This was about as good as it gets.
Reassembled all aileron parts with cleco's.
Riveted almost all parts. Only have two rivet holes to fill - those directly under the counterweight arms. Have yet to figure out a way to get a riveter in there. Other builders have suggested the original-style pop-riveter that is quite narrow. Of course, the aviation dept at Lowe's didn't have one. Will check Harbor Freight Monday (is on the way home from work).
Test-fit the aileron to the wing (picture 3 below).
