In this section, the first step is to locate and notch the hinge pockets, and remove 1/4" from the wing trailing edge in order for the aileron counterweight to clear during it's travel. The 8" hinge is the most inboard, 5" from the inboard end of the well, and the 2 6" hinge are spaced out 31" center-to-center from here. These hinges are cut from the 6' piano hinge offset (the curve of the two sides are opposite). I went ahead and cut the rudder hinges first since they are not offset, and the pulled the hinge pin and reversed the halves.
Once the hinge pockets are located, they are notched 3/16" deep with a Dremel. I used my 6' straight edge to make sure they were all inline with each other. The pockets are then chamfered to clear the curving portion of the hinge arm, and then 3/16" mounting holes were drilled (2 in the 6" hinges, 3 in the 8" hinge). The hinges were then attached with 3/16" clecos, and the straight edge was clamped to them to check travel. Later the clecos were to be replaced with protruding AN screws, but I elected (after discussing it with the factory) to replace these with counter sunk screws and Tinnerman washers.
Aileron Hinge Fitting
We had one aileron with a significant twist in it. We heated it with a halogen lamp and applied weight to it to straighten the trailing edge off an on for a few nights which eventually worked the twist out.
Fixing Aileron Twist
Wing in dining room
Aileron Hinge Installation