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  A Dremel extension is glued with Bondo to a Wood straight edge which slides against a one inch aluminum guide strip. The guide strip has been superglued to the surface of the wing.



  This results in super straight cut lines for the aileron.



  The wing aileron trough can be carved out with a sanding drum and must be deep enough to allow full down aileron deflection.

It is a good idea to install the ailerons temporarily by supergluing the hinges onto the wing.

It is surprising how much room is needed. Don't forget to allow room for the several layers of glass in the rear spar, and a little micro and paint on the ailerons.



  These jigs were made on a band saw from 3/4 inch plywood in about ten minutes, and along with the small wedges are used to hold the aileron in place while the aileron hinges are bonded into place.



  On the top surface, a tight gap between aileron and wing reduces blow through from the high pressure region below which would disrupt the airflow above the wing and create drag. The aileron top surface is jigged so that it is just proud of the wing surface. This improves aileron effectiveness for small aileron deflections.



  The aileron to wing gap is held very accurately. Small lengths of wood strip were used to jig the aileron while the wedges were put into place. It is important to allow room for the aileron leading edge to swing into the aileron wing trough with plenty of clearance.