The next major project will be to fit and install the wingtips, but first I need to find a way to hold the ailerons in the correct position so I can make all the trailing edges line up. The plans are fairly silent on how to do this – probably they expect that the bellcrank alignment fixture will suffice. But I wanted a more positive means to align the ailerons with the flaps, so I knocked together these jigs out of materials I had on hand:
The center piece is made of 1/4" nylon, strictly because I had a chunk of it laying around, and the angle pieces are lined with UHMW tape so they don't scratch the skins. When installed, they hold the ailerons tightly in line with the flaps, with hardly any play:
On the bottom side, the bungee cord hooks around the inboard aileron hinge and keeps the alignment jig from backing off:
I copied this design from a type of gust lock I've seen used on DC-3s… in fact, I may eventually repurpose these as gust locks for the RV. In the meantime, I now have a way to hold the ailerons in the proper position for fitting the wingtips.