When I first fitted mine there was no way to get the pins in. Each wing wasn't in enough making the overlap in the center of the spars about 2-3mm offset (felt with both wings in place and ratchet straps used to snug them up).
It was obvious on mine that the spar stubs were slightly too long stopping the wing seating properly/fully.
To fix this I used the old method of 'painting' the ends with a marker pen (should have ideally used engineers blue but didn't have any).
I then pushed each wing from the tip and gently wiggled up and down so I could see the high point where the ink wore off.
This was then filed lightly and the whole process repeated until the holes lined up.
This was before any root seals were fitted.
It took quite a few hours doing this, I didn't want to risk removing too much material in one go so I basically spent two days doing shallow squats while pushing the wing in with my back
In the end I left it where the pins are still tight to get in (straps and rubber mallet required) and one pin is slightly harder to get in than the other.
As I don't plan on removing the wings other than inspections I decided I would leave it tight until I have the first inspection, to give them time to bed in if needed.
At the first inspection I may need to do a bit more adjusting to get an easier fit but I'd rather they are tight than lose
The hardest part is working out what is stopping them going in. Adding some marking to the stubs and simply pushing them in and wiggling up and down (not too much up down) will show if the stubs are butting up against the carriers or not (no shiny metal where the marker is rubbed off means they aren't touching so something else is fouling)
Just make sure you are 100% convinced that you have the correct point of fouling before getting out the files/snips and go slow with removing material.
Originally Posted by Alex Edwards
I had a similar issue. Check where I have circled in the image in the post at the link below.
When you put the first wing in can you put your finger in the hole that the pin goes into? How far out of alignment are you?
Just a note that the later kits (mine anyway) had an extra bit of paper with it saying to remove the material you mentioned. It wasn't in the plans if I remember correctly but a sheet of A4 with the part itself. I guess a lot of people had issues with the fitting at that point.