After finishing the big aileron pushrods (previous entry) I continued the day by checking aileron throws. It was at this point that I discovered that the brothers I bought these wings from had failed to install an aileron stop on the right wing.

I fabricated the stop for the right wing per print and determined an approximate location by drawing a sharpie line on the inner aileron bearing bracket with the aileron held to the appropriate deflection as measured with a digital inclinometer/level.

Removed the aileron and attached the new stop to the bracket via a #40 pilot hole and a cleco. installed the aileron again and checked travel, then determined that I had 32.4 degrees up travel. Per section 15 of the build manual, aileron travel is 25-32 degrees up 15-17 degrees down.

0.4 degrees as measured with harbor freight cube level isn't significant enough to worry about, but the boys had the other stop installed to allow about 29 degrees of up deflection. It would bug me to know that they weren't symmetrical, so I made a new stop with the pilot hole in the stop shifted slightly and checked again.

Took couple of iterations, but ended up with hard stops as follows;

Left: 29* up 16.8* down
Right 29.2* up 16.7 down

Sure happy with the result, but wait, there's more.

A lot of guys forego the metal stops completely in favor of a stop made from a round delrin spacer on the bolt that holds on the upper smaller aileron pushrod. This has the advantage of a softer stop without the metal on metal banging if caught out in the wind.

I would have gone that way 100% except my second hand wings already had a metal stop riveted on the left side, so I elected to match it on the right.

However, since my hard stops are on the high side of the operational range, I think I'm going to play around with the idea of installing delrin stops as well, limiting travel an extra 1/2 degree or so in order to have the ailerons hit the softer stop first. If the delrin fails I've got a real belt and suspenders installation with the hard stops or if the installation doesn't work out for some reason, no harm done. Thats a project for next time!