Well, I got the hinge recesses done. What a PITA!!!
First I cut the foam in the Port aileron and the foam didn't cut very cleanly. Bunch of gouges but at least the angle was OK. Stardboard aileron was much better by cutting the foam and leaving a good amount which I then sanded with a wooden block that I cut at the correct angle of the Vee. That worked a lot better. Then I glassed the Port aileron first following Rowland's advice of placing all layups in poly sheet and then transferring. That worked well except that the line of glass at the LE came out to wavy for may perfectionist taste. I changed the technique a little bit and the Starboard layup came up much better. Oh well, I guess that in these cases you get to perfect the technique in the first and do better on the second.
In any case, it looks like such a small job and it ends up taken an inordinate amount of time. But this is a milestone. The ailerons are now skinned.
Following are some pictures of the work during the weekend.
Port Aileron done. Note the cradle. It's amazing what you can do with stuff you find around the house and it actually worked great :)
Here is a picture of my epoxy pump setup. Pictured here is a mixer I build many years ago for the Cozy build. Everyone says you cant use mechanical mixing because you get too many bubbles in the epoxy. So I designed this mixer to turn very slow and to scrape the walls and bottom of the cup as it is mixing. I have a timer that runs it a preset time (I have it set at 5 minutes now). When the mixer finishes, I manually mix for another 30 seconds making emphasis in scraping the walls. The epoxy comes out perfect with no bubbles. This lets me work while the mixer mixes another batch. I'm just too lazy to sit there mixing epoxy :)
Next weekend I will trim the glass layup I did this weekend and will start work on the flaps. I am trying to get all large layups done this summer to take advantage of the heat to keep the control surfaces as light as possible. I will work on the closeouts during the week if I can since there is no need to do large glass work for those items.
So to close this posting, yesterday I was working on this layup and by my taxiway, Lo and Behold, a Europa taxies by!!! I ran after it to find out that it belongs to my neighbor Alan Burrows. Just two houses from mine! This is a gorgeous airplane and it sure is a motivator for my project. He's going back to England for the summer but told me he would take me for a ride when he got back. Can't get any better than this :)