The cable should not touch the aluminium skin and the phenolic acts as a guide and is okay touching the cable. The closest cable is the top one when aileron is down and sometimes it is necessary to dimple the aluminium downward so as not to contact cable. Check for frayed strands.

I wanna install an aluminum fairing on top and bottom, so need to know how deep to make it.

Imagine something like this



So need to know the cable travel in the worst io/down position for both uper and bottom exit way.

I don’t know the measurement but the cable attach horn will give an idea and add a tad for clearance. Sometimes one has to adjust the offset hinge arm up or down with a pipe to set the neutral aileron flush on same plane as wingskin

Mine was already installed so hopefully it should be a plug and play... ahahah I've learned the hard way there is no such a thing in building a plane.

Reason I want to install a fairing is that when I opened the wings, inside they were basically in mint conditions. Except where the ailerons cables leave out, and the flaps mechanism inspection cover. I've reenginered the top one to be water tight flush mounted, and the bottom one with plexiglass so to visually inspect the mechanism.

Wheel tubes, do they have a straight or bent valve stem?

Main wheels straight but offset.
Tailwheel bent.
Alaska Bushwheel no tube. Inflate tyre from sidewall.

Main wheels, 8.0-6, I can only choose straight or bent valve stems.

Straight should be corrected. I believe the offset Jermey mentioned is it's position clocked about 30* off center line.

What paint was used back in 1981 to spray the wings?

I would bet Randolph aircraft paint. The question of whether it was a urethane or not would have to go Maule or Jeremy.

Way back when... paint was Randolph Maule White E-8073 Butyrate and Enamel. Up to 1981 Razorback fabric was used then later Ceconite 101A
Previous name for the creamy white was Daytona White. Duane, correct me here.

What is the gap within the wing trailing edge and flaps/ailerons leading edge?
Is it easy that the 2 come in contact, or almost impossible if things are normal?

As close as necessary so that leading edge of control surface does not contact wing trailing edge when in full up or down extension and so that at neutral the bottom of control surface is flush with wing bottom skin.

Ok, say the curved portion of the trailing edge is not perfectly smooth is slightly bended in and out, and I had to put a reinforcing backplate outside riveted to the flap/aileron hinge/reinforcing plate inside the wing. Do I have the worry this will get I contact with the flap/aileron leading edge or they are quite far away..

What is the gap, 1/2 in, 1/4in?

There’s no precise measurement as it varies with the curve. You just have to fit and adjust skins or hinge posts for clearance