The recommended fix is to move the aileron torque tubs and the pivot point back 1/4″, then cut the trailing edge of the aileron and shave the rest to match the contour of the wing. I looked at numerous other approaches, but most would involve starting from the rib fabrication stage, or simply building all new ailerons. I had considered simply notching the aileron nose spar, but just wasn’t really comfortable with that idea.
I needed to enlarge the holes for the torque tubes in the plywood plates that close out the aileron bay. To do this I found a sanding drum for the spindle sander that, as luck would have it, slid snugly onto on the aileron tube itself. I was able to use this to oval out the holes enough to position the aileron where it needed to be. The most difficult part was holding the aileron perfectly in position forward/aft and up/down to align with the wing ribs. A bunch of clamps finally got that done, along with a pair of spacers to position the aileron the correct distance from the front of the aileron bay. With it securely clamped in place, I drilled the holes for the bearing blocks. I’m glad I didn’t sell off my right-angle air drill that I bought to build the RV-7; it was really the only way to get those holes drilled. A full size drill or chuck wouldn’t fit without hitting the adjacent rib and the torque tube.
Next up will be using a plane to shave a quarter inch off of the trailing edge and correct the taper to blend this with the rest of the wing. The nice thing is, I have the technique and the tools I need now to do the other wing, and it should only take half an hour or so instead of the few hours I spent on it today.
I also found a couple of areas where I had missed applying spar urethane, so I got those all painted this morning. There’s only a little work left to do on this wing before I will be able to move it to the airport and bring the other wing home.
