RE: Acceptable aileron hinge gap for a Trainer?
Time pilot,
There is an easier fix for this. Right now you have the groove in the aileron cut so that the torque rod is flush with the top of the forward edge of the aileron. Cut the groove a little bit deeper in the aileron so that the edge of the aileron is against the trailing edge of the wing, and so the torque rod now sits a little deeper than the edge of the aileron.
Ken