Going back to the stress calculations. I made some more 'accurate' measurements using my 1/48 scale model...hehe
I figure the ailerons span about 50 sq ft of wing surface. From the center of the aileron to the wing folding joint is about 8 feet. With the outer wing panels being some 95 sq ft, I figure a torque load of about 170000 lbs.ft at 7.5 G is the limit.
I ran the airfoil (NACA23009) through the analysis program with aileron deflections of 19 down and 14 up. Here's what it spit out!
The ailerons change the lift coefficient by about 0.5. Doing the math for various G loads, I came up with the following speed limits:
1G - 540 mph
2G - 490 mph
3G - 450 mph
4G - 390 mph
5G - 330 mph
6G - 260 mph (Note: This is only barely achievable before stalling)
I would say that full deflection could be used at higher speeds, depending on G load, but that in keeping with the 300 knts force limit, you were pretty safe, regardless of any G load within the allowable limit. there was still a 50% margin of safety on top of that.