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match drilling elevators

I am frustrated with the results of match drilling the elevator horns.
We used the block of wood. taped and clamped the elevators to the horizontal
stabilizer. after taken every precaution the holes are not perfectly aligned.
which translated to the right elevator not even with the left.
HOW DO I FIX THIS??
 
Tig

I am frustrated with the results of match drilling the elevator horns.
We used the block of wood. taped and clamped the elevators to the horizontal
stabilizer. after taken every precaution the holes are not perfectly aligned.
which translated to the right elevator not even with the left.
HOW DO I FIX THIS??

Take the elevator with the hole closest to a edge to a TIG welder. Have the welder fill the hole. Sand smooth, paint with matching rattle can and drill over. Use two of these to hole the elevators locked in trail.
https://www.harborfreight.com/12-in-handscrew-clamp-60551.html
 
When you say not perfectly aligned how imperfectly are they?

There is very little affect in flight if they are slightly off one another and there is a chance for your next try to be of small imperfect alignment again abut the option for fixing it, is described above.
 
Thank you all for responding. Big help. Bavafa I did not measure the difference in elevator alignment and I should have included a pic. "Perfect alignment" was not the correct description . It was enough difference that other builders said it should and can be fixed.
Thank you Tom023..... I just got back from the welding company and
attached the left elevator to the horizontal stabilizer. HOORAH great match.
Round filing and extending the mismatched hole then welding the washer gave me the results I was looking for. I had a 2nd washer welded on the inside of elevator horn for extra support strength.
 
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