Fit the wingtips. Right tip drilled and clecoed #40 shown in image 1. At the leading edge, the molded tip was stiff so drilling the fiberglas was not an issue. Further back, used blue tape to support (somewhat) the glass to keep it nearly in contact with the skin. Still had to use very gentle pressure on the drill and wait patiently for the drill to break thru.
Overhand of wing skin was variable, with 0.460" the smallest distance. So trimmed the tips for a consistent 0.460" flange width from the molded line. Additional cutouts (image 2) required to clear the outboard aileron bracket, in addition to the rear aileron swing going all the way to the tip.
Unfortunately, I mis-measured the aileron relief on the right tip (image 3). A thumb's worth of clearance is a bit more than needed.
The left tip was measured properly and needs some sanding to have a ~1/8" gap between tip and aileron. The great thing about fiberglass is you can put more on (as well as take it off), so I'll splice some of the material I removed back on to the right tip to make both gaps equal.
Right wing in cradle, tip drilled and clecoed. (Pix rotated 90 deg ccw)
Cutouts for aileron bracket and swing on the right tip
Too much relief for aileron swing. (Pic also rotated 90 deg ccw)
