After riveting the bottom skin, I flipped the wing back over right-side-up and clecoed the top skin back onto the skeleton so I could align and drill out the left aileron. In order to do this, I have to also clamp the left flap back onto the wing (previously drilled out as part of the bottom skin prep) to ensure proper alignment/spacing. With the flap clamped to the bottom of the wing, I proceeded to install the left aileron to the top of the wing.
Installation was a learning experience. Between moving the flap out of the way to attach the aileron actuator rod, getting the aileron hinge to slide between the skin and the rear channel all while making sure the aileron balance bar stayed aligned I finally managed to wrestle the aileron into position. Desired spacing from the flap is 5mm. Mine was 7 mm and the outboard end of the flap jutted out a couple of millimeters which didn't look good. The culprit was the balance bar pressing up against the inboard edge of the hole in the rear channel which allows the balance bar to extend into the main wing body.
So I took it all apart, widened the hole about 3mm (thank you Mr. Dremel!!) and wrestled everything back into position. Perfect. 5mm on the dot.
Next I added weights to the balance arm while the aileron was attached to the wing. The goal is to get the aileron to balance even with the top of the wing without any tension on the whole aileron assembly. It seemed to take a lot of weights, but it's all balanced.
The aileron hinge drilled out with the aileron attached. Flap in the background clecoed from under.
5mm spacing - no interference between the aileron and flap.
The balance bar with weights attached viewed from inside the wing.
