After adding to 2 and 1 plies of BID yesterday I was shocked to find out that I could have used up to 4 plies in order to raise the aileron enough to be flush top and bottom with the wing. I must have really removed a lot of glass. Good news is the beds are very stiff and since I had the stiffness there, I opted for filler as a bed rather than glass because while the filler is still soft I could install the aileron and press the hinges into the filler creating a perfectly flush bed. Now the aileron is flush and right where it needs to be. The second task was to get those darn TE's the match the wing. So here's the deal, I went to the Rough River fly in today and critiqued everyone elses EZ's in contour and alignment and was SHOCKED at the poor workmanship that I saw. It's incredible that some were even airworthy. Nevertheless, a few of them had ailerons with the same TE issue that I'm having and i was tempted to call it good enough. However I put a little more muscle and precision into sanding the TE's on both the aileron and wing and found that I could get them lined up just enough without adding too much weight. The final result is an aileron that is now much more balanced and 7lbs 4oz prior ro primer. I am guessing that my THIN primer application is going to put it right at 7.5lbs. This weight is still a little heavy but within .5lb of the other aileron. Flutter testing will be done in very small increments!!!! Finally I was able to add filler and skim to the rest of the rudder and look forward to flushing it with the winglet tomorrow. Last of all I finessed the trim tab and added filler for a smooth transition. I have 1 more run of filler to go and my wing will be ready for primer. Exciting day!
