September 2, 2008 ... Today marks the two year anniversary of my Sones project. While I am still awaiting parts to re-fabricate the left aileron, I decided to go ahead and fit the left wing tip. The wingtips provided with the kit are fiberglass. Using my Dremel, I carefully cut the required clearances for the main and rear spars.  When the time came to fit the wingtip to the wing, I was deeply disappointed by the fit. The wing tip fit very poorly. While it was a big disappointment, I was not overly surprised. Several other builders experienced similar problems (See Jeff Shultz, and Dennis Burton's websites.)

September 3, 2008 ... After sizing up the amount of work I would have to do to make the fiberglass tips fit properly, I decided not to use them, and scratch build the wingtips out of .025 aluminum. That will be plenty challenging but I think the metal tips will last much longer and I will have better control of the fit with much less work.

So, the first step was to produce a template of the precise shape of the wing. I did that by securing a piece of 1/4th inch hardboard to the end of the wing and drawing the contour of the wing with my ultra-fine line Sharpie pen. I then cut out the pattern on my bandsaw, and touch-up sanded to a nice clean edge on my disk sander. The template will be used to determine where the flanges will be bent.

September 7, 2008 ... I have some .025 aluminum sheeting on order for the wingtips, and  received my left aileron replacement parts from Sonex on Friday. So I spent a couple hours today fitting, drilling, snd deburring the drive rib and counter-balance parts. 
Left aileron ..."Take Two!"

September 9, 2008 ...  Today was a productive day in the shop. I alodined all of the left aileron ribs; re-assembled the left aileron counter-balance and drive rib; made the necessary cut-outs on the aileron skin and pre-drilled the skin and ribs. You will notice from the photo that I did not cut the compound angle on the outboard end of the aileron. I am going to wait until the aileron hinge is assembled to the aileron and the wing. Then, with the aileron attached to the wing, I will draw the vertical angle on the forward side of the aileron, based on the existing angle of the rear spar, pull the hinge pin, and make the compound cut
accordingly. This will assure a perfect match between the aileron tip and wingtip.