Hey guys, I was looking at this forum for some help because today I spent about 30 minutes trying to line up holes for the three screw plastic control horn.

So far, these are the techniques I have read about here.

1. Mark hole drill locations
2. Use a pin to push through and create line-up holes for the screws to travel through (I tried this one today, with limited success)
2a. Alternatively, use a drill press
3. Bevel the tip of the screws to a 45 degree point, so that it is easier to line up and enter the plate on the other side.

I was thinking about using the drill press to create the aligned holes on a piece of 1 inch thick x 5 inches long x 2 inches wide wood, then bevel it lengthwise to achieve a desired angle (so that the holes are drilled as perpendicular as possible to the chord line) . Once done, secure the guide with tape to the control surface, and use a regular drill so the holes come out aligned on the other side. The only hard part in this is to properly bevel the wood guide so the set of three holes come out straight through on the other side.

Another alternative would be to make a guide with enough beveling so it supports the control surface on the drill press mount, and use the drill press itself to make the three holes. Again, the hard part is sanding the correct angle onto the support guide...

Any commercial guides available?

Will try it out sometime today, and see how that goes.

UPDATE.
While looking for some more tools, I found these tap and drill guides at Harry Higley's website.
[link=http://www.harryhigley.com/75TapNDrillGuide.htm]http://www.harryhigley.com/75TapNDrillGuide.htm[/link]
On that page, scroll down past the 5 step wing bolt drill process, on the new section without numbered steps, the third image shows an aileron being drilled for a wire insertion. He has installed a piece of scrap wood to align the aileron chord with the surface, and although he is drilling parallel to the surface with his tap guide, you can do the same process for a perpendicular drill using a drill press!