4/27/23 - 1.0h
Once again, I started my plans review by looking for changes, bulletins, and updates on the Van's website. There was one change to the plans back in 2015, which was incorporated into the version I already have. I didn't spot any other relevant changes.
The first thing I noticed in the aileron plans is the structure is a little different than the wings, elevators, flaps, … The main difference is the counterbalance rod in the leading edge and very few leading edge ribs. The hinge brackets are also a different design than other control surfaces I've built so far.
Step 3 on the first page of instructions after the overview drawing appears to have some typos. Step 3 instructions abruptly end, followed by a repeat of the step with additional instructions labeled Step 7. Step 3 (7) is buffing the curved portion of the nose rib flanges to avoid a faceted appearance. I've done that in several previous assemblies, so it is easy enough to get the intent of the plans despite the typos. This page also does not instruct the builder to countersink the holes in the inboard hinge brackets where the nut plate inside the inboard nose rib attaches, but the figure specifies AN426 rivets for the nut plate, so the hinge bracket definitely needs to be counter-sunk.
It was interesting to note that the counterbalance rod is made of stainless steel, and the instructions say it need be primed. Similarly, the trailing edge wedge and trailing edges of the skins aren't primed since adhesive will be applied there for final assembly. It looks like some care is required in the initial steps to ensure countersinking, dimpling, and final/match drilling is done correctly. The final assembly appears to be very similar to the flaps, so hopefully there aren't any surprises there.