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Date:  1-5-2011
Number of Hours:  1.00
Manual Reference:  6ZU4-6+
Brief Description:  Drill inboard rib for left aileron counterbalance

This effort took place in small steps over several days.

1. I started by drilling the 3/32 pilot holes, top, bottom, and front for the inboard aileron rib. Jeff Garrett had posted a note on-line stating that he had interference between the counterbalance weights and the wing structure at the LAA specified location, and he recommended a location ~100 mm inboard. I thus measured a position exactly 100 mm inboard. That was a mistake. I should have adjusted the position to align with existing rivet holes for the aileron closure joint on the top of the aileron. Oh, well. I now have some extra rivets.

2. I had trouble holding the rib in position to drill the pilot holes down from the top. I decided to drill in the holes for the front and to cleco the rib in place while drilling the top and bottom holes. Unfortunately, that gave me minimal edge distance for the top holes, so I'm saving that rib for the outboard rib on the right aileron, and I started over with a new rib. With hindsight, I should have drilled the pilot holes to attach the balance arm, and used clecos to hold the rib in position while I drilled the top holes. I ended up drilling the front holes to #20 as I tried to adjust the rib, given the (somewhat) misaligned front holes. After drilling pilot holes, I drilled 1/8" and #30/

3. Per the instructions, I marked and 3/32 pilot drilled the holes for the balance arm in the inboard rib. Then I clamped the balance arm to the rib, carefully checking that the angle was 97° from the top-front of the aileron and that the middle pilot hole was centered on the arm. I 3/32 drilled the middle hole through the rib and into the arm. Then clecoed the arm to the rib, re-checked the angle, reset the clamp and drilled an end hole. Clecoed and drilled the other end hole and clecoed again.

4. The instructions state that the ribs should be aligned with the table top and a square, as shown in Fig. 1. This does not allow for the fact that the ribs are not perpendicular to the front of the aileron.
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Ribs aligned per photoguide instructions

Ribs aligned per photoguide instructions

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