I am starting on the left aileron for my airplane. On the Bede BD-4C, the ailerons are operated by 10 foot long torque tubes which run from the fuselage, through the flaps, all the way to the wing tips. Here is a picture of the torque tube for the left wing with the aileron ribs (temporarily) attached. You can click on this photo, or any other, to see a larger version.
I made a whiz bang fancy dancy drill guide to assure that I drilled straight down through the rib and the center of the tube. You can see why it is handy to have a 6 inch long drill bit.
Here is a “close up” with all three ribs drilled.
After drilling these holes, I took the ribs back to my drill press and used a 5/8 inch spade bit to counterbore the holes. When I attach the ribs to the torque tube, the bolt heads and the nuts will be recessed into the ribs and I will not have holes in the aileron skins.
