Okay so cutting ailerons free from wings is much easier than it seems. It also makes it easier to build a good fitting aileron because you build the aileron as you are framing up the wing.
First off the tools that you need are a razor saw, a #11 Xacto blade, a metal straight edge and a pencil.
I like to remove the blade from the razor saw so that I can cut deeper with it.
First, push the Xacto blade through the sheeting right up against the rear face of the rear spar, toward the inboard end of the aileron.
Then put a pencil mark on the sheeting right in line with the knife blade, and then repeat this toward the outboard edge of the aileron.
Now use the straight edge to draw a line between the 2 marks, this will depict the aft edge of the rear spar.
Next, use the razor saw to cut the sheeting in between the aileron butt rib, and the wing rib and then repeat this on the other end of the aileron (if needed).
The reference line we drew before is the stop line, don't saw any further or you will be cutting into the rear spar.
Now, put the straight edge back up to the line you drew. Using the #11 blade cut along the line, don't try to cut the ribs we'll do that next, just cut the sheeting.
Now, use the razor saw to cut the ribs free. Make sure to keep the razor saw blade right up against the rear face of the spar, but be careful not to cut into the spar. Don't worry about the rib ends being a little ragged, when finishing the ailerons that will get cleaned up.
And wahla! The aileron should pop free.
Last thing to do is clean up the sheeting and the ribs in the wing with a sanding block, making sure to sand the sheeting flush with the butt ribs as well as the sheeting up against the rear spar.
