Initial Prep (Debur, Trim, Drill, and Cut)
5/6/23 - 1.2h
5/8/23 - 1.8h
5/9/23 - 0.5h
The aileron spars came out their vinyl coverings to start this step, and I decided to debur the spars now to ensure the aileron nose pieces go together smoothly for the remainder of this step. I am building both ailerons together, like I did with the flaps, and the first formal task for this step was clecoing the nose ribs and doubler to each spar.

The plans specify 879.5mm as the length of the stainless steel tube counterweights for each aileron. I measured each tube with some trepidation at attempting a straight cut accurate to 0.5mm, and was excited to see that Van's supplied the counterweights already cut to the proper length! The only thing I had to do was lightly debur the ends.

Preparing the counterbalances continues by clecoing the nose skins to the spar, which in turn holds the counterbalances in place. Once the nose skins and counterbalances are locked down, the holes at each end of the counterbalance are match-drilled to the nose skin. I used a drill guide to help me drill perpendicular to the hole in the curved nos skin, and then cleco'd the holes as I drilled them to ensure no movement while I worked on the opposite end holes. The spar is then removed from the assembly to complete this step.
[Hole and Edge Deburring Tools, #40 drill]