Transfer drilled the hole pattern from the left aileron AEX wedge to a piece of OSH Al angle. Countersunk the AEX wedge using the jig shown in Image 1. The hold down clamp keeps the wedge from skittering back and forth with countersinking the second side. The csk pilot is steadied by a #30 hole drilled in the maple block that the wedge rests on. (The edge of this block is sawn at an 11.5 deg angle.) But when the 2nd ctrsnk breaks through into the first, the AEX material itself can move, causing chatter and ugly holes, instead of beautiful holes like the one in Image 2.
Buck riveted the nose/main skins to the spar, and squoze all but the last two rivets of the main ribs near the TE, so the wedge can be pro-sealed, insterted, and clamped to a straight edge. The Al angle in Image 3 straightens the edge quite nicely--deviations << 0.1" which was considered good enough to the Emp's TE's.
I may decide to use the line of holes in the table top made when the AEX was first drilled to get the TE even straighter?
