Spent a large part of labor day laboring on the right aileron. Last day of a much-needed 4 day weekend with perfect garage weather and no other activities on the calendar.
Started off by locating and match drilling all of the ribs including the two gussets which were match drilled to ribs #1 and #2.
Per page 8 of the 6-ZU-4 Aileron Upgrade instructions I only located and drilled the inboard balance arm rib. The other will be drilled after installing the balance arm.
My original fitting of the tip rib was causing a bowing/buckling of the lower aileron web bend so I fabricated a new rib and did a better job of locating and match-drill sequencing resulting in a very nice fit along the front web.
Created a cutout in the front aileron web for the aileron horn. Used a 15mm strip of aluminum to locate the center of the 5/16" control cable hole. With end rib removed I clamped the bottom of the horn flush with the bottom of the rib and match drilled the 4 A5 rivet holes.
