The aileron needed 30 deg down deflection from neutral position, but we were only getting 25 degrees. We trimmed a little bit of fiberglass at the front edge of slots in the aileron leading edge that were hitting the hinge, and that helped get us to 29 degrees deflection. At this point, we ran into another issue as the fiberglass no longer interfered, but one half of a new aileron hinge bracket that we made was now interfering. We noticed that when we made this aluminum hinge bracket, it was slightly wider than the one we replaced, so we filed down the edge slightly which gave us more clearance. Once we corrected this, we were able to get close to 32 degrees deflection down, which is sufficient.
We also began planning for installation of the aileron pulleys on the right wing. We clamped the lower pulley in place temporarily, and need to check alignment carefully before drilling any holes. We ran into alignment issues on the left wing that required us to make a new bracket, and may run into similar issues with the right wing. Hours 2.0
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