We rolled the wing over in the rotisserie so it's now bottom side up again. At a glance we could see that the inboard end of the aileron was almost 1/8” closer to the bottom sheet skin metal than the outer end. In other words, the gap between the trailing edge of the wing and the leading edge of the aileron was tapered. This could have been a discrepancy in the shearing of the skin, but on closer inspection, we think the cause is a difference in overall length between the tripod hinge mounts which are used at the pushrod locations and the bipod hinge mounts which are used elsewhere.
The flap has three hinge points, the middle one also being the pushrod location, which resulted in an inward bowing of the centre of the flap when it was installed on the hinges. (corrected with washers under the hinge mount) In the case of the aileron, there are only two hinges. The inner one has the pushrod and again, it was brought outward by installing washers under the hinge mount. The gaps between wing skins are looking nice and uniform now.
The trailing edges of the flaps vs the ailerons are quite different as provided. They are temporarily pop riveted in place and can be moved in or out prior to final riveting. I'm reticent you go too far with this though, since the aileron trailing edge skins get kind of ��ushy��or less rigid when moved very far out past the back of the aileron ribs. Conversely, when they get moved in too far, they get a puffed up or rounded look from being stuffed up over the ribs which does not conform to the overall shape of the control surfaces which is otherwise quite triangular. We will lay some string to arrive at the best location and if required, pinch some of the aileron and flap ribs a little thinner.
We also mounted the aileron carry-through cable (Which goes from one aileron bellcrank a cross the cabin roof to the other one). Unfortunately, it currently touches the flap pushrod when the flaps are down. So the holes in the adjacent ribs must be raised until there is clearance (about 3/16��. I think the best solution is to make the holes bigger and then use larger nylon snap bushings. I verified this with Mark G and with an AME friend and they approved. I have some snap bushings ordered from ACS, but it turns out they are available for about 1/20th of the price at Fastenal right here in Airdrie. I'll try tomorrow or next week.