Finally got a little time to work on the project. Spent about and hour playing with the rear template placement jig and the rear channels.
When I had my last major question, I was trying to determine the jig distance for the rear channel ( 380 or 400mm ). I called Zenith and Roger gave me a better way: do not even use the jig. His suggestion was ( working center outwards ) to square the ribs, place the wing channels and THEN drill the angle to the channels.
Having already jigged the long sets, I decided to do this for the short channel.
Here is the problem: I first test fitted the 600mm channels and the angle ( 7V6-3 ) was not protruding far enough from the channel. The mating surfaces were about 3-4 mm apart. The obvious fix is to trim away a small portion of the flange from the wing rib. Because the piece must be 600mm for proper rib alignment, moving the 7V6-3 or the fabricated end cap are not options.
I'm still going to follow Roger's advice for the shorter channels since I can trim the entire channel for clearance before adding the 7V6-3 and still maintain proper edge distance.
Wings: 26.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
Total Done: ~130 hours