First the good news, Van's is statisfied with my trim tab, just a bit of sanding. Then a repaired the counterweight by melting some lead and filling the holes.
After that it got more difficult, while drilling the new holes in the counterweight I could not align exactly with the rib's flange. I first decided to fabricate new flanges.



Then second problem. I have difficulties with countersinking. It's not the tool, but more my poor technique. In the picture you can see the tool "wandered" and ovalized the hole though I had backed up the thin flange. As this is the secondary spar whers the trim tab will be attached, I ordered a new part and also order the ribs I misdrilled this morning.



To finish the day I worked on the trim tab and drilled the hinge. What needs to be done while waiting for the parts is said in only three words: deburr, dimple and prime. Small sentence but long hours ahead.