At 12:54 PM 1/3/2016, you wrote: >I saw that potential clearance issue with the hinge & angle too. I >guess the angle could be trimmed a bit to give clearance.
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++ The drawing for the setup using the aluminum angle looks to over complicate things and adds unnecessary weight. Follow the directions on page 87 and 88 of the manual. That setup works just fine. The 1/2" cut back on the bottom side of the aileron after removal from the wing allows for sufficient down travel of the aileron. Note how the two hinge halves are separated by the hinge pivot for correct spacing. Adapting a setup from other aircraft will only complicate things. Trying to get the layer of cloth that the plans call for to wrap the spar to the skins will be tricky. The 90 degree corners will not want to lay flat. Lay them on the bias or I found multiple layers of the "deck cloth" (very lightweight glass) worked better as it made the 90 degree corners better. I don't think the drawing at the top of page 88 is totally correct as it shows the spars parallel in the neutral position. I think there should be a wider gap at the bottom to allow sufficient down travel. Double check the cut back on the bottom side of the aileron for correct assembly (top of page 87). Once the height of the two spars are determined, cutting the angle of the bottom edge using a table saw or similar makes for a nice fit. Larry Flesner
