James,
This goes back a few years, but I think the best approach is to grind back enough of the ribs to clear the aileron. Then grind a notch in the aileron to clear the hinge bracket. That reduces the size of the notch so that it isn't too noticeable. But you will be able to see the notch with the aileron in the neutral position. The notch on the bottom has to be large enough to allow installation of the hinge bolt, quite a bit larger than the notch at the top.
Gary Casey
After initial fitting of the aileron on my slow build ES, I need to notch
the upper skin to allow travel, and the lower skin to allow access to the
hinge bolts. The manual is not very helpful with suggestions, other than to
keep the notches to a minimum, as they will be visible. For the upper
travel, I can remove some of the trailing edge ribs, to allow a lot of
travel without notching more skin. How have others handled this issue?
James M. Anderson, III