RE: Help with Aileron Repair
Use 30 minute epoxy mixed with microballons to fill in the hole you have there. Don't worry if you don't have microballons on hand, you can substitute corn starch and it will do exactly the same thing. First of all, secure the aileron in the center position. And also make sure that the torque rod is centered too. Mix up the epoxy and mix in the cornstarch/microballons. Fill the hole with the epoxy mix, make sure that you work the mix all around any gaps between the torque rod and the wood of the aileron, and then let it dry. You can then sand the epoxy smooth with the aileron surface and recover the area with covering material (monokote or ultracoat). I've made several repairs like this before they will hold up just fine in flight.
Hope this helps
Ken