I positioned the aileron in the neutral position and then used a straightedge to mark the trailing edge of the wingtip.  For some reason, it’s made a little long and needs to be trimmed about 1/4″.  I cut off the excess and then filed back to the line.

The trailing edge of the wingtip was now much thicker than the trailing edge of the aileron, so I cut the web that was joining the upper and lower pieces.  Somehow, this caused the trailing edge of the wingtip to no longer be in line with the aileron, so I had to split part way up the side as well to allow it to shift back into position.

I mixed up some epoxy/flox and glued the outboard end of the trailing edge back together with a little preload in the direction the tip needed to move to be in line with the aileron.

I drilled additional holes in the hinges that will rivet to the wingtip so that I can form some epoxy/flox “rivets” between the aluminum rivets.

I countersunk the right wingtip and then riveted the hinges on.  You can see the epoxy/flox “rivets” here.  Afterward, I spent a little time cleaning out all of the epoxy that squeezed out around the hinge eyes so that it won’t interfere with installing the hinge on the wing.

I trimmed and drilled the right wingtip tonight.  This went substantially faster than the left side.

In preparation for drilling the wingtip to the hinges, I cut a piece of XPS foam and inserted it between the hinges to keep them from flexing inward when drilling.

I installed the wingtip and taped it in place with some clear packing tape.  I drew a line 7/8″ outboard of the row of rivets holding the hinge to the wing and marked lines even with all of those rivets.

Finally, I drilled all of the holes to lock in the wingtip’s position.

I installed one of the hinges to the outboard end of the wings a long time ago (like two years!).  Since I had practically the whole day free to work on the plane, I decided to wrap these up so that I could start fitting the wingtips.  Afterward, I started fitting the left wingtip.  I trimmed the flange so that it will slip into place, but had to stop before drilling it to the hinges.