Installing the flaps and ailerons took longer than I anticipated. I thought a couple of hours and a few bolts and everything would be in place and ready to go, but I found that I spent a lot of time on details to get everything in place and operating without hiccups.
Getting to the hardware for the Ailerons is though. There isn't quite enough room to get your fingers in there. To get the washers installed on the outside surfaces of the bearing I borrowed (stole?) Glenn's idea as shown in the first image. A piece of tape holds the washer in to the tool, and once in place with the bolt pushed through just pull the tool out.
Getting the nut on the end of the aileron bolts took some patience. I ended up wrapping a little piece of double stick tape on the end of a long cotton swab, and using this to get the nut positioned, at which point I could get a finger on it and turn the bolt to get the threads started.
When I started connecting the aileron pushrod I found the ball joints on the bell crank were binding. While the pushrod could be pushed into place without much effort, I wanted to fix the issue. I slipped 4 thin washers on a 1/4" hex head bolt, then a 1" long tube spacer, followed by a nut to hold it all tight. I chucked this in my drill and ran it against the belt sander until I had reduced the diameter of the washers to the diameter of the bolt head. I installed these above and below the ball joint bearing, and I changed the two thick washers to thin to keep the overall stack up length the same. This offered plenty of range of motion without binding.
