Brief Description: Pilot drilled the aileron hinge to wing rear spar
I decided to drill the aileron hinge to the rear spar before fitting skin so I could check the short aileron pushrod clearance. Several people have had issues and had to enlarge the main spar pass-through and add washers or spacers between the aileron control horn and the bearing. After drilling the aileron hinge to the rear spar and attaching the aileron.
I too have this problem, the measurements provided on the plans are simply wrong and some parts are incorrect. There are 3 critical locations for the short aileron control rod. The main spar pass-through location, the aileron horn location and the aileron rod slot in the bottom wing skin. These three locations simply do not line up properly.
It appears the best solution will be to enlarge the main spar pass-through hole side towards the root of the wing, the inside edge of the hole needs to be extended another 1/16 to 3/32 inches to provide clearance for the rod. Also, for the rod to be centered in the lower wing skin slot, it appears washers or a spacer will be required between the aileron horn and the push rod bearing to move the rod end out away from the inside root.
I've decided not to do anything until I pilot drill the skins to the wing which should insure the wing structure is square. Once drilled, I will lift the top rear inside skin and see what the clearances are at the spar pass-through. Will then remove the skins and enlarge the hole as needed. Will contact Sonex first because I don't like grinding on the spar without their approval. Not sure if I will need a spacer between the aileron control horn and the bearing. I may just widen the lower skin slot as needed to provide clearance and then cover the slot area with a fairing.
I'm not a happy camper right now, I'm disappointed Sonex has not corected these issues by now, not sure if other builders are simply not reporting the problems or what?
