Great Planes Extra 300S 40 Kit - GPMA0235 - Manual (Page 19)

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11. Position the left aileron on the trailing edge of the
wing, then mark the location of the torque rod and the end
of the aileron where it meets the tip trailing edge.
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12. Cut the aileron approximately 1/16" shorter than
the mark you made at the tip so it will fit in the wing.
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13. Use a drafting square or triangle to extend the
marks to the front of the aileron, then use the “centerline
technique” we've shown you before to mark the centerline on
the entire leading edge of the aileron.
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14. Use the centerline and the marks you made
earlier as a guide to drill a 1/8" hole in the aileron for the
torque rod, then cut a groove in the front of the aileron for
the torque rod. Use the same 1/8" sharpened brass tube
you used for the elevator joiner wire.
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15. Test fit the aileron in the wing to make sure the
torque rod fits and there is approximately 1/16" clearance
between both ends of the aileron and the wing. Make
adjustments if necessary.
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16. Mark the location of the hinges on the aileron and
the wing. Cut the hinge slots, then test fit the aileron to the
wing with the hinges.
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17. Remove the aileron from the wing. Mark the
“bevel to” lines and shape the leading edge of the aileron to
a “V” as shown on the plan the same way you did for the
elevator and the rudder.
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18. Perform steps 11 through 17 to fit the right aileron to
the wing.
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19. Use light weight balsa filler such as HobbyLite to fill
glue joints or dents in the wing. After the filler has fully dried
use your bar sander to sand the wing using progressively
finer grades of sandpaper so it is smooth and all the joints
are blended.
Nice looking wing! Wait until you join it to an equally
aesthetically pleasing fuselage.
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