Step 1:    Cleco the bottom skin assembly to the spar/main rib assembly as shown in Figure 1. Final-Drill #40 the holes common to the bottom skin assembly and A-1005-L and -R Ribs. Deburr and dimple the main ribs and A-1002 Bottom Skin. A low profile  dimple die is necessary for reaching the aft most rivet in the main rib to skin attach flanges. Fabricate a female die by drill and countersinking a thin steel bar such as a splitting wedge Note: I used my vise grip dimple die and it worked well!

Step 2:    Rivet the bottom skin assembly to both A-1005-L and -R Main Ribs with only two "keeper rivets" (temporarily) rivets per rib as shown in Figure 1. Do this at the second and fifth holes from the forward edge of the A-1002 Bottom Skin. Just partially set these rivets since they will be drilled out later. The deeper rivets will eliminate the need for clecos and allow the aileron to lie flat while the upper surface is being drilled.

Remove the clecos from the ribs and run the assembly over bottom side down.

Step 4: Cleco the A-A004-L and A-1004-R Nose Ribs to the A-1009 Counterbalance as shown in Figure 3.

Cleco through the aft side of the spar to attach the nose/counterbalance subassembly and A-1014 Spacer to the spar assembly.

Step 5:   Cleco the A-1015-R Inboard Nose Rib to the spar assembly.

Cleco the A-1001A-L Nose Skin to the bottom flange of the A-1003-L Spar and to the A-1004-L, A-1004-R, and A-1-15-R Nose Ribs. Bring in the top skin assembly and cleco it along with the nose skin to the top flange of the spar at every other holes.

Cleco the top skin assembly to the A-1005-L and -R Main Ribs. Allow for some empty space along the main ribs so that a board can be positioned over them to weight down the aileron.

Step 6:    Lay the assembly flat on the table top hanging the clecos which are holding the A-1001A-L Nose Skin to the A-1002 Bottom Skin and A-1003-L Spar over the edge. Use weights over the main ribs to keep it firmly against the table with no twist. A straight board can be used to distribute the weight and hold the aileron flat to the table as shown in Figure 4. Also the flanges of the A-1005 Main Ribs may be clamped to the table top to ensure they stay flat.

Step 7:   Check the A-1001A Nose Skin for bowing with a straight edge held span wise midway between the leading edge and spar. About 1/16 inch of rise is acceptable. If necessary the skin can be squeezed down by hand to minimize the bow.

Final drill #40 every other  hole in the A-1003-L Spar.  Move the clecos and final-drill the remaining holes.

Final-Drill #40 the holes common to the nose skin, A-1002 Bottom Skin, and the spar from below. Use an extended drill bit.

Final-Drill #40 the holes common to the A-1004-L and-R Nose Ribs and A-`1001A-L Nose Skin.

Final-Drill 7/64 the two A-1004-R Nose Rib to A-1001A-L Nose Skin holes that receive blind rivets. See page 21-6 Figure 5 and Page 21-5, Figure 4.

Final-Drill #40 the holes common to the A-1015-R Inbd. Nose Rib and to the nose skin.

Final-Drill #40 the A-1001B Top Skin and A-1005-L and-R Main Rib holes. Reposition the weight as required.

Step 1: Cleco the A-1001 Trailing Edge, made from VA-140 Trailing Edge extrusion, into the aileron's trailing edge and trim as shown in Figure 1.

Drill #40 holes common to the top skin assembly, trailing edge and bottom skin assembly.

Note: Drill perpendicular to the centerline of the extrusion, not the surface of the top skin. The difference is only a few degrees, but using the correct reference will give better results.

Step 2: Disassemble the aileron. Drill #40 to remove the keeper rivers installed earlier. For the technique on drilling out rivets see the illustration near the end of section 5 titled "Working with flush rivets". Deburr all the parts including the insides of the lightening holes in the A-1003-L Spar. With the exception of the A-1001 Trailing Edge dimple wherever exterior flush rivet will be installed, including the spar flanges. Since the spar is .040 thick it may bow slightly when dimpled but it will straighten during final assembly. Machine countersink the holes in the A-10011 Trailing Edge with the tool perpendicular to the surface of the part.

Dimple all remaining holes in the skins.

Prime as desired. The 1009 Counterbalance is stainless steel and need not be primed.

Step 3:Rivet the two A-1008 Doublers to the A-1003-L Spar as shown in Figure 2.

Rivet K-1000-3 Nutplates to the spar with the rivet heads flush on the doublers forward side.

Cleco the A-1014 Spacer to the spar.

Step 4:   Attach the A-1004-L and A-1004-R Nose Ribs onto the A-1009 Counterbalance using the hardware shown in Figure 3. if you have difficulty getting a screwdriver on the head of the screw use an offset screwdriver or a Phillips bit tip held Vise-Grip pliers at 90 degrees.

Cleco the nose rib/ counterbalance subassembly into the A-1001A-L Nose Skin. Cleco the A-1015-R Inboard Nose Rib into the nose skin by installing clecos into the counterbalance and all nose ribs.

Step 5:   Rivet the A-1004-R Nose Rib to the A-1001-A Nose Skin as shown in Figure 4. For rivet call outs see Page 21-6, Figure 5. The solid rivets can be set with a hand squeezer.

Blind rivet the two nose skin to nose rib holes as shown in Figure 4.

Caution: Damage to the nose skin may result if solid rivets are substituted for the blind rivets shown in Figure 4.

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