February 1, 2005 - Right Aileron
Deburring.  It's tedious, but I don't mind it.  Edge-smoothing is the task I dislike the most. 
Dimpling. 
Rivet the nose rib to the counterbalance weight.  Cleco the nose rib to the spar, then cleco the leading edge skin on. 
Cleco the trailing edge to the leading edge - spar assembly.  And now we're ready for the dreaded next step:  riveting the leading edge and trailing edge top skins to the spar.  It was a bear with the left aileron. 
But this time, it went fairly smoothly, I think because we had the technique down.  Here's how we did it:

Lay the aileron upside down with the leading edge hanging over the edge of the workbench.  I use the gun from below while Lynnette holds the bucking bar from above.  She used the rectangular bucking bar this time.  I used scotch tape to keep the rivet in place, just like back-riveting.  To keep the aileron from falling off the workbench, I used rope tied to the bench and running through the trailing edge.  A heavy toolbag rested on the trailing edge skin as well. 

It was still a tiring process to sit on the floor and shoot the gun upwards, but we got it done in less than an hour, and the rivets came out well -- only had to drill one out. 

Here's a better look at the rope keeping the aileron on the beach, along with the tool bag. 
After the top skin riveting was done, the rest was a piece of cake.  Just hand-squeeze the end rib rivets, then pop-rivet the bottom skin to the spar.  The can and bowl resting on the trailing edge are full of clecoes and are to keep the aileron as flat as possible on the workbench. 
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