The aileron hinge covers were quite a bit more complex to make. The lower aileron hinge covers have to match the leading edge curve; I ended up using a 1 inch OD steel pipe to bend the covers around. It is difficult to keep the bend aligned perpendicular to the long axis of the hinge cover. The inner aileron hinge support bracket has medial and lateral support angled tubing which the covers have to clear by cutouts. When installing the covers, first the lower covers are installed without the pushrods connected with the ailerons fully deflected upwards. Then the upper covers are installed. The cutouts should be made to match the pushrod-installed aileron. It is also only barely possible to install the hinge covers without disconnecting the control cables from the aileron bellcrank. I still need to radius the corners of the covers, Scotch-Brite and otherwise smooth, degrease, Alodine and prime them.
Rivnut installation, nutplate holes drilled and dimpled.
Inboard aileron hinge cover prior to support brace trimming.
