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Joe's OneX #129 Project
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Date:  9-27-2013
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Modified aileron counter balance hardware #1

The plans hardware call-out for the aileron counter balance weight assembly will not work. The AN3 bolt alone is wider than the wing skin cutout and fairing. Some people have used a countersunk screw on one side and low profile nut on the other but that still doesn't provide clearance on the nut side and the support arms may have to be bent to get the assembly centered in the skin cutout.

I decided to use countersunk screws on both sides of the bracket which would allow for 1/4" clearance on each side of the bracket and the skin cutout. To do this I needed to tap the holes in the lead block so the screws could be screwed into something. Taping lead is not a good idea so I purchased some thick wall aluminum tubing 1/4" OD and taped the inside of the tubing after cutting it to length (width of the lead weight). I enlarged the lead weight holes from 3/16" to just under 1/4" and pressed the threaded aluminum tubes pieces into the lead weight.

I used 5/8" countersunk screws with RED Loctite to attach the weights to the support brackets. This hardware change will result in a slightly lighter counter balance, hopefully not too light.

See additional pictures on next posting......
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Lead weight and taped inserts

Lead weight and taped inserts

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Arbor press used to insert threaded tubes

Arbor press used to insert threaded tubes

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Weight with threaded inserts in place

Weight with threaded inserts in place

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