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John,

The plaster, much to my surprise, held up very well with no apparent
interaction or distortion.  The plaster mold was in a chipboard box with
the
thickness of the plaster not less then 10m, but I don't think it is
critical.  I am sending a sketch of the wood mockup separately to your
email
address.  The mockup should be oversized, and get thinner as you move
outboard.  The idea was to use the available space to the maximum.  I
made
one ~ 60 cm weight per aileron.  They were left 1875 gr. and right 1251
gr.
in the final  trim.  Am also sending a sketch of the shape when
finalized.

When casting don't overheat the lead.  My experience was that
overheating
leads to cavities.

To fit the weights I bolted them to the flange ( three 4-40 screws and
nuts),
put three layers of duct tape on the wing cavity to simulate the final 2
bid,
and filed down the weights until I had the manual deflection plus 2°.  A

rough wood rasp is fine for the initial trimming.  I then bonded them
flox,
put the screws back in and did a 2 bid layup.  I vacuum bagged the 2 bid
on
the right aileron and will probably redo the left in view of the
difference
in quality.

Hope this helps a bit.  If you want more details let me know.

John

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Please send your photos and drawings to marvkaye@olsusa.com.
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