good thing you let all the spots dry (from where your sweat was dripping onto the balsa!) before you took the photos!
would have been fun to watch a heartrate monitor as you stepped up to cut them! unless you've done it a bunch of times before, then it's business as usual.
i've never done foam wings so it's looks a little scary from where i'm sitting (in case you didn't figure that out!).
I thought you were kidding with me.
OK, I take it you have some insight into that step, otherwise, you would not have made the comment.
Many different ways of doing that step...
This will be my 6th pair of wings that I prepare that are foam core and balsa sheeted, for 40% airplanes.
I will elaborate...
#1 . have someone else do it for you.... this is what I did on the 1st set of wings, in fact, Tony Russo sheeted them for me, and then my partner, who is a hand surgeon, he cut them out for me, in his shop, using a large band saw. He did a great job!!
2. the 2nd set of wings, I did it myself, using my small band saw....
not really a problem, since you make sure you err on the '"buffer zone", and not cut into the good sheeting, but the one that will be removed, since we remove a 1" strip.
the 3rd way of doing it, which is much easier.
is to get a long ruler, and mark out the aileron on both sides, and using a very sharp blade, cut thru the balsa only, using the ruler as a guide.
do both sides, then remove the balsa strip, and then using a hot wire, cut thru the foam, the balsa will be the guide. it is, the easiest way of doing it, and safest. Also, you do not want to use any thing that is too hot, as this will burn more foam, and you will have a depression on the surface.
no matter which way you do it, I use a sand belt on a flat surface, and then move the wing and the aileron to and fro, until it is perfectly flat and smooth. Just a few strokes is all that is required. then you can glue on the LE and TE of the hinge line.