Hi all,
Chris has the answer. I have uploaded another photo showing a mockup of the ailerone linkage hopefully you can see that the horns look more at 90 deg with the ailerons.
In future I will set the horn holes as the point that has to be at 90 Deg to the aileron not the torque rod wire! It seems obvious when when you think about it . I seem to remember a saying about wood and trees. May be the manufacturers of the torque rods could put instructions on the packet for dimbo's.
Thanks once again for all your help again how did we ever manage without the internet ? so many friends when you need them.

Regards,
Richard.