Brief Description: Laid out, cut and pre-drilled ailerons
First I made the two aileron horns from .063 6061-T6 aluminum. They were easy to make and came our fine. I then marked the inboard rib location, marked the cutout for the aileron horn and removed the material, measured the complex angles on the outboard end and made the necessary cuts. I then made my 13mm spacer (to establish the washout on the outboard tip), placed it and pre-drilled all holes except the hinge line. One of the fun things to do was temporarily place the aileron tips (6-W-2-4) in the outboard end to check the angles and fit. They looked like they were meant to go there...which, of course, they were. By carefully following the plans, some pretty remarkable alignments occur.
Straight on view of aileron horns and outboard ends
Perspective view to aileron outboard ends with tip in place