After spending some time analyzing and calculating bend lengths and developed lengths I realized that the "Triple Bend DL Calculator" of Larry Winger's Bend Line Spreadsheet was a bit oversimplified. The bend (sight) lines for bends 2 & 3 were calculated by just adding the specified lengths of Webs B & C to the sight line for bend #1. However, as I learned from the right aileron this creates Webs B and C that are each about 2mm too long because it does not compensate for the offset of each successive bend. After subtracting 1.8mm from the 2nd and 3rd sight lines calculated from the spreadsheet I was able to bend up an aileron skin that matches the print dimensions of 94 and 305mm within about 0.5mm; as close to dead nuts as I can get using simple measuring and bending systems. After all 3 bends were complete I matched up the skin to my previously-forms ribs and discovered a near perfect fit.
This was certainly some nice mental therapy from the chaos of what my job has become lately. Hoping for a change back to the account for which I was originally hired so I can regain some sanity and time.
