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Adam,

See if you can get a straight edge on the aileron hinge line to see if it is curved.  One of my Legacy ailerons had obviously been built with too large of a middle rib.  The factory jig-drilled the hinge, making the holes equidistant from the edge as are those on the aileron.  Furthermore, when the top wing skin was attached during the builder assist program, the skin matched the bulge in the aileron, thus the hinge has a bend in it which causes it to bind as the aileron is moved.  One solution I have considered is to get a hinge half and re-drill the attach holes on a curve so that the hinge stays straight.  Another is to cut the hinge into 2, 3 or 4 sections to eliminate the binding caused by the bending pin.  The smaller sections would also allow the use of teflon sleeves and stainless pins since the sleeves are immpossible to insert in long crooked hinges.

Scott Krueger
Legacy #106

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