With regards to joining wings, In the past for a built up balsa wing I've always used some sort of plywood brace. My last two patton models utilized foam wings. The wing halfs were joined together with PVA wood glue and a 150mm wide glass bandage of around 163g cloth and epoxy. The models are still flying today.

The Aurora wings were butt joined with PVA and a epoxyed glass bandage.

For cutting the ailerons, I use the same method as PROPBUSTER, place the wings in there outer cores, then run them through the bandsaw. This way you can be sure the leading and trailing aileron edges are straight.

Thanks ATLANTA 60 for giving some kind of comparison on the wing weights, I feel a little more at ease

Mike