I've got to post a follow up to this thread.

While my wallet saved up money for the batteries to fly this bird, I did more and more reading.

Last week, I came across a build thread by RCKen. Seeing how well he did on the hinges on his build, and see how blankety-blankety-blank-blank bad I did on mine. I decided "make it right."

I ripped the monocoat off my wings. And I'm rebuilding it now. The wing's TE is so buggered up, it wasn't useable. So I ordered a new TE and ailerons from Sig. (Should be here next week)

In the meantime, I've modded the wing for independent aileron servos (flaperon if I want).

The biggie, I practiced cutting slots. I used scrap TE and aileron stock to make practice.

I have the slot cutting tool from GP. Works great!

I do have a couple questions. Hopefully RCKen will see this and respond. I followed his technique.

When CAing the hinges, should there be any gap between the TE and the aileron?

The first picture shows my first attempt. No intentional gab between TE and aileron. Seems OK, not sure. The second picture, I left the pin in while I moved the aileron to it's extreme, before CAing the hinges. There is a gap, slight. The pin is being held in place by friction, that's how close it is.

Which did I do correctly?