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Date:  1-26-2008
Number of Hours:  3.00
Manual Reference:  N/A
Brief Description:  Disassemble aileron trim, deburr, etc

1. Drilled a 7/16" hole in the front of the aileron to bring the trim tab cable out of the aileron.

2. Drilled a 3/16" hole in the front of the aileron to attach an MS21919 clamp for the cable.

3. Disassembled the trim tab and channel from the aileron.

4. Deburred all holes and scoured joint lines with ScotchBrite.

5. Vacuumed out the aileron between the two middle ribs.

6. Cleaned the joint lines with laquer thinner.

7. Primed the joint lines with Cortec 703.

8. Built a new edge rolling tool. The handle is made of 3/4" wide x 12 gauge steel.I used the spare set of Nylon rollers that were supplied with the Avery edge roller that I purchased some time ago. The rollers are attached to the handle with 0.5" 8x32 AN screws. The new tool and the Avery tool are shown in Fig. 1. I drilled #19 holes in the handle to accept 8x32 screws. The Avery rollers have a built in 8x32 nut. I put a thin washer under the rollers.

I found that the round, hockey puck handle on the Avery tool made it hard to control and use the tool effectively. Also, the large protrusion of the handle beyond the rollers made it impossible to use the Avery tool in many places because the handle collided with the structure of the part. The new tool is modeled after the tool that EAA Technical Counselor, Clayton Wilhelm uses. See Fig. 2. His roller used ball bearings instead of Nylon rollers. I might make another one with ball bearings, some day.

I used the new tool to roll the edges of the aileron cutout. It worked quite well. I felt that the new tool made it much easier to control the roll angle. The Avery tool would not work at all on those edges because the handle bumped against the other edge of the cutout.
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New edge roller & Avery tool

New edge roller & Avery tool

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EAA TC Clayton Wilhelm's tool

EAA TC Clayton Wilhelm's tool

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