Had a question from a builder if I had made the aileron fairing. I hadn't so thought I'd give it a try. The part has multiple bend back, bend up joints, so one sequence of bends might be easier than another.
First I layed out the bend lines and hole locations. Then smoothed all the edges. Next drilled the outer holes with a 3/32 bit (sht F01). These will transfer to the wing skin as starter holes for the #6 sheet metal screws. The fairing holes will then get updrilled to 5/32" for sheet metal screw clearance.
I ended up doing the inner 90 deg bends first on a small Harbor Freight brake, then the outer 90 deg bend by clamping it in the fixed part of the brake and bending by hand.
The 46 deg bend was done by hand using a 2x4 block to bend against. The legs needed to be trimmed for the bend to close completely.
The 31 deg bend was done last because its location might vary depending on how close the 90 deg bends came out. Bent that with a hand seamer (Harbor Freight 66654). Finally the 15 deg bend with the seamer until it came out flat to the table.
