Deburred parts awaiting corrosion proof.

Dimpling the relevant holes for the nutplates on the inspection hole doublers.

Likewise for the upper hinge line of the servo tab.

The upper hinge line on the aileron were re-drilled with #30 bit.

The result after being re-drilled with #30 bit .

Having marked 1.25" spacing on the lower hinge line, #40 bit holes were drilled first.

The upper hinge line fully drilled with #40 bit holes.To be re-drilled later with #30 bit.

Positioning and drilling the upper hinge line on the aileron with #40 bit first.

Drilling four holes on the servo horn through the lower skin.

Had not done my project for a while due to base check recently and second backorder shipment problem. Will resume project after clarifying the servo deflection with Glasair Aviation soon.Here, the servo tab in right up position ready for further drilling onto the main aileron.

Drilling the bottom servo tab with #40 bit.

Drillling the upper servo tab with #40 bit first.

Lots of work had been done at this stage mainly positioning marking all the rivet holes both on the top and bottom of the servo tab aileron.Drilling will commence again tomorrow...

The hinge was trimmed such that the first knuckles are 1" from the edge of the tab. Here, it was inserted in between the upper aileron skin and forward servo spar.

The forward spar was inserted between the two aileron skins with the 97 degree flange on the lower surface and the end of the spar flush to end ribs.The spar was taped for now.

The outboard end rib was trimmed to 6.5" length while the other inboard rib was trimmed such that it flushed with the uupper and lower skins while cleco-ed in position.

Similarly, 23" x 2-13/16" of material was cutteed out from the lower skin.

Using my newly acquired digital Dremel 400 series tool(purchased from Bunnings ,Perth for S$220) , i sliced the 23" x 2-15/16 " piece of alcad like a butter at 24,000rpm from the upper skin of aileron inboard end . In the process, i broke 3 pieces of cut-off wheel . Lesson learnt.. not to rush in cutting. SLOWLY DOES IT.

Using my newly acquired Dremel tool (purchased from Bunnings,Perth for S$220), i cutted the 23" x 2.86" piece of alcad from the inboard end. Btw, i broke 3 cutoff wheel in the process at the end of the day. Lesson learnt..to take cutting as slow as possible with no rush.

Duplication on the other inspection hole cover.

The rivet holes of nutplate K1000-08 drilled completely. Note additional two #40 holes drilled through the lower surface of the skin and lower spar flange, one on either side of the aft nutplate.

Here, I am seen drilling the rivet holes of nutplate for the inspection hole cover.

Next , moving forward along the nose rib , #40 rivet holes were drilled with exception of the forward most hole in each nose rib which was drilled with #30 . Also, the outermost nose ribs at each end were drilled entirely with #40.

Moving aft along the aft ribs, #40 rivet holes were drilled . The aft most holes on the two inboard aft ribs (reserved for antiservo tab) were not drilled.