The manual clearly states to cleco the skin plate to the lower skin when transfer drilling the skin to the frame. I saw this and then forgot about it (a disadvantage to building with the jig in the horizontal position since the bottom skin is somewhat hidden). Anyway after transfer drilling the top skin I flipped the stabilator over and noticed that the skin plate pilot holes did not line up with the skin pilots when the plate was properly positioned against the actuator horn. The holes were about 3/32" off. This was a silly mistake on my part, I should of flipped the stabilator over and reviewed the alignment prior to drilling. My solution was to build a little jig and over bend the skin plate along the skin bend line, ten bend the tab back to 90 degrees along the control horn bend line. This shortened the plate and everything fit up acceptable. Still it ended up taking about a week since for a while I was too aggravated to work.
jig to rebend the skin plate at control horn interface
fix in, continuing to transfer drill lower skins
Skin plate bent to match pilots and horn 90 degree angle
