"Dear Lord, please help me not to judge the person that did such a horrible job building this aileron....Amen." :)
So the aileron needed to be extended on it's leading edge by almost an inch. This meant the entire forward face of the aileron had to be cut off, stripped, all parts removed and new foam put in place. Surprizingly after only 6.5 hrs I'm almost ready to lay up the glass. The hardest part here was sanding down the pour foam to the correct angles and keeping them level. No instructions on how to re-build the aileron but I don't see a problem in building up the lost glass and overlaying the 1 ply BID on the front side per plans. The only difference will be glass that is butted rather than a single piece. I'll be creative in my layups to avoid butted joints as much as possible. I will say though, that after doing this work, I would have NO problem building new ailerons from scratch, or even making them into berkut ailerons for better roll :) I can see 2 new ailerons finished in less than a week if I decide that my 7lb right wing aileron is too heavy for safe flight....we'll see. So far not too frustrating here in the shop.
