While waiting for the replacement aileron skin to arrive, I started on the aileron spars and reinforcement plates. The plates are fabricated from 0.040″ sheet, and match-drilled to the aileron spars. The only trick here is making sure that the spar orientation is correct…outboard vs inboard, left vs right.
I also bent the right aileron trailing egde using the bending brake mentioned above. The piano hinge I bought at Home Despot looked to be a good idea at the time, but after a couple of bends I noticed that the hinge eyes were flexing a lot and not squeezing the trailing edge as I would’ve liked. Before I bend the left aileron, I think I’ll replace the piano hinge with regular heavy-duty door hinges.