Brief Description: Prepare & pilot drill L Aileron for piano hinge
1. Per direction from Zenair, cut the front of the flex hinge flange, leaving a flange 20-mm wide.
2. Cut the piano hinge to length to match the aileron. I removed the hinge pin and cut each half of the hinge separately with a hacksaw. At the outboard end, I matched the angle and length of the original flex hinge flange.
3. Cut a long piece of L-angle to form the bottom attachment flange for the piano hinge.
4. Mark the hinge attach flange and the bottom flange of the L-angle for pilot rivet holes. I choose to align the hole positions on the two parts.
5. Pilot drill (3/32") the hinge attach flange and the L-angle. I did not drill the L-angle pilot holes for the counterbalance arm support ribs, because those would need to be aligned with the corresponding support rib pilot holes in the aileron front. With hindsight, it would have been better to not drill the support rib pilot holes. Then I could have marked and pilot drilled the appropriate locations on the L-angle. That would have been an easier way.
Fig 1 shows the hinge flange supported on a 2x4 before pilot drilling--see fig. 2.
I love my ATS airdrill. I can drill much faster than with my electric drills, though I wish I'd bought a quieter air compressor.
