As far as I know, I installed the two ailerons to the trailing edges of the wings exactly as per the manual. Since all the holes were pre-drilled and all the parts pretty much pre-fabricated the finished assembly should have all fit properly. Unfortunately, as a hangar mate (and helicopter mechanic) pointed out to me, there was really no gap between the outboard end of each aileron and the wing tip. The parts scuffed against each other and resistance could be felt when actuating the ailerons. After a lot of thought and procrastination I decided the only answer was to slot each of the six hinge's mounting hole slightly so that each could be shifted 1/8" towards the centre of the plane. I first tried to do the slotting myself with a 1/4" reamer bit and my drill press but couldn't hold the work piece tightly enough. So I had a local machine shop do the work. In addition to the AN4 mounting bolt, each hinge is also fixed with two stainless steel rivets. These I put through the same holes in the hinges but had to drill new 1/8" holes for in the trailing edge of the wing. I did enlarge the holes to 1/4" diameter for the first 1/4" into the hinge to ensure that the rivets reached into the wing far enough. Over 6 days, spread over 5 weeks, fighting the weather and lethargy, I got the job done!
