RE: Help - how to build ailerons from finished TE's
Sorry, no pictures. But, I mark the hinge line on the top of the surface, then mark the lines for the additional material that needs to be removed from the new T.E. of the wing and the L.E. of the flight surface. You need to do this to allow for a solid piece of material which will be used to glue your hinges into. Example. If you are going to use 1/4" balsa for the wing T.E., you would mark a line 1/4" forward of the hinge line. Same goes for the leading edge of your aileron except you will mark that line 1/4" behind the hinge line. The material between these two lines will be removed and discarded. With the above example, you will remove 1/2" total material between the wing and aileron to allow for the new T.E. and L.E..
To cut the surface free, you can do it slowly and carefully with an Exacto and a straight edge, or quickly and easily with a scroll or band saw. Once you remove all of material to allow for the new T.E. and L.E., sand it straight and glue on the new T.E. and L.E..
Once the glue dries, plane/sand these pieces flush with the wing and control surface. Bevel the control surface in your favorite method and you're done. Don't forget to remove enough material from the ends of the control surface to allow for capping these areas or you will be left with open ends for both the fixed and moveable surface. Example, if you are going to cap with 1/16" balsa, you will need to remove 1/8" material from each end as you must cap both the fixed and control surface.
John