Fix rear spar outer connection angles
The rear spar outer connection angles WG-ANG-010-X-A- had incompletely formed bends, perhaps also a small positional error. This would normally be grounds for rejection, but the radius of curvature is very large, approx 3.5mm. Reforming is a possibility. The ~1.5mm excess profile of this angle beyond the rear spar extension throws off the aileron hinge position, the top (skin 5) and bottom (skin 2) skin attachments, and the position of the end rib 11, as well as the tail skins 8.
TAF confirmed a radius of curvature of 3.5mm for this 1mm thick bracket. I constructed an anvil with an approx 3mm radius of curvature by shaping a 90 degree steel section and used this to clamp the part in position then rolled the bend with a nylon hammer.
A perfect fit for all items was achieved without the need for fine tuning. The only exception are the holes where the skins 8 attach to rib 11 and skins 5 and 2. Some of these holes are about 2mm out of position, particularly on the top side. This is being discussed with TAF.
The original bend was "rolled" with none to negligible opening up of any part of the existing bend. The risk of weakening and/or cracking is thought nonexistent and the parts will be used.

this flange should line up with the end of the spar channel extension

aileron hinge is pushed away from the end of the spar channel extension

severity of hole mismatch if the hinge is bought into position

skin 5 fit is affected

6mm ROC forming anvil

forming complete

before (left) and after (right) reforming, the bend was rolled - no concerns about inducing weakening or cracking. The EkoPrime was not dislodged by all the hammering.

perfect alignment for both brackets

no readjustment required

final result after clean, but will reprime
This post is from Adam Dickson
Main wing spar surgery - Summary