I'm currently drilling the holes for the robart hinges that I'll be installing on the ailerons of a GP Extra .60. Given that the surfaces on the ailerons are not parallel but they meet at an angle, using the robart drill jig doesnt deliver a perfect hole. I drilled two holes that came out a bit off center. I want to re-drill them but I dont want to do it in another place in the aileron as it would result in an uneven installation when compared to the aileron at the other side, not to mention that I already glued bass blocks on the inside of the aileron to receive the hinges. What should I do? I'm thinking of filling the hole with titebond and then insert a balsa scrap piece to fill in the hole, then I can drill again. The only concern I have with this method is that when I drill the holes again, they can follow the same path that they did before. Any thoughts on this?

Fill and plug as you mentioned (Titebond & balsa) then re-drill carefully with a 3/32" drill, using a press if you have one available. The smaller drill will be less apt to follow the old hole. Then drill them out to full size

The only thing I would add is to use a brad point drill. It will offset the tendicy to follow the glue paths, some what. It is also easier to get started "on the mark"


Don