Tonight I re-checked both A-705-L ribs to the left outboard skin to verify the mismatch. Still there. )O: I also took some careful measurements of both aileron skins, and determined that outboard end of the left one is shorter that the others by 1/32" to 3/64", and its holes are that much closer to the trailing edge than the others.
I sent the following email to Vans this evening:
To: "Van's Builder Suppoort"
"When I cleco an A-705-L rib into the upper side of the outboard end of the left aileron skin (A-801-1PP-L), I get about a half hole diameter misalignment on the bottom side, as shown in the attached photo DSCN3861.jpg. When I force clecos into the bottom side, the trailing edge of the skin curls up as shown in photo DSCN3895.jpg. Removing the clecos lets the skin relax to its proper contour as shown in DSCN3901.
Both A-705-L ribs received in the kit cause the same problem with the outboard end of the left aileron skin. Both of those same ribs fit the inboard end of the right aileron skin properly. In measuring the upper side of the outboard end of the left aileron skin, I find that it is about 1/32 to 3/64 shorter from trailing edge to leading edge than the upper side of the inboard end, and both ends of the upper side of the right skin. Also, the rib rivet holes are about 1/32 to 3/64 closer to the trailing edge than the other end, and the upper holes on both ends of the right skin.
Is this skin mis-bent or mis-punched from the factory?