With everything on the left Aileron completely drilled and cleaned up(deburring holes and edges) I needed to counter-sink the Aileron spar. Now I've read that the depth of these can NOT be too much as the #40 clecos holding that leading edge cuff on will not adequately keep it in place. So I tested and tested on a scrap piece before I committed to the spar. I will leave the countersink cage set and do the right one as well.

Once we had the Aileron Stiffeners in place we needed to get each assembly together one more time to get the leading edge cuff on... and this was no small undertaking. We were beginning to wonder if this would even fit but after some thinking and the two of us using a lot of positive reinforcement we got it together. The reason to do this is simply to get the final trailing edge drilled and the few holes on the leading edge of it through the stainless pipe. Here is what is looks like getting it ready for drilling...

Drilling it at the correct angle is important for proper back-riveting and shop head.

and the leading edge #30 holes drilled through the stainless pipe.

Laying out the Ailerons and diligently marking them.

From Pete and Tad's RV-9a Build

then onto marking just a few Stiffeners for inside each Aileron.

From Pete and Tad's RV-9a Build

From Pete and Tad's RV-9a Build

after they were matched, deburred and primed it was time to back-rivet them in place.

From Pete and Tad's RV-9a Build

From Pete and Tad's RV-9a Build

With the majority of the tanks behind us now I carried on with the Ailerons and fixing the leading edge assembly (that we put together at Tad's place) onto the Left Wing Spar. This is a pic of the fuel tank assembly together with the leading edge assembly. Each of these will get riveted to the main skeleton of the wing.

From Pete and Tad's RV-9a Build

Here is the Leading Edge assembly final riveted on the Wing Skeleton. This riveting is virtually blind except for only a few... not easy to do.

From Pete and Tad's RV-9a Build