Time to build something NOT straight
The ailerons have a twist of 3/16" over the entire lenght (nearly 8
feet). To set that, I spend a good half our finding straight
2"X4" at my local renovation store. I position the skin (after
the ribs are clecoed on the bottom) on the 2"X4" and to make
sure it is stable, I installed some lead bags on each ends. I also used
liberate amount of duct tape over the lenght of the aileron.
Who wants to fly with me? :-)
Before risking to ruin my nice right wing aileron, I decided to check how I
would install the trim tab on my fake aileron that I previously made to verify
the fit of my skin with the ribs.
After several attempts, I finally found something that works and is not too
bad looking. (ok, not on this one...) I would have preferred to
install the servo motor directly on the access door... but this did not work
as the servo is too large when the rod is extended.
The real thing Once I was satisfied with a prototype, it was quite easy to replicate it
on the aileron. The only thing I hope is to never have to change the
trim servo... it was quite difficult to install the cotter pin in that tight
space (the short side is 45mm wide).
Aileron attached to the wing
This process is quite simple. Insert the aileron flange between the skin
and the Z, align the aft of the aileron with the wing tip, measure to ensure
the aileron position is constant from end to end, and drill.