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Date:  1-9-2008
Number of Hours:  3.00
Manual Reference:  6W2 8
Brief Description:  Aileron control horns, right aileron

1. Make aileron control horns:

- Drill 4 #40 pilot holes for rivets per dwg. 6W2-3.
- Drill a 5/16" hole, 12-mm from the other end of the part.
- File the corners to a radius of 12-mm around the center of the 5/16" hole.

2. Drill #40 and cleco one control horn to the left aileron, taking care to meet the 15-mm standoff distance between the 5/16" hole and the front skin. See Fig. 1.

3. Disassemble the left aileron in preparation for deburr.

4. The front flange of the L tip rib is shown in Fig. 2. The small holes are the original #40 holes drilled with the tip rib inserted to 9-mm edge line depth. The larger #30 holes are the extra three holes drilled plus the holes through the original 3 pilot holes drilled to #30. See Fig. 2.

5. Adjust the rails so that the rails are level at the pivot point as described in the 1/7/07 log entry and the W-rail is 13-mm higher than the E rail at a point 1-aileron length S of the pivot point.

6. Place the aileron skin right-side up on the rails so that the outboard trailing edge was elevated 13-mm above the forward edge. I found it useful to place spring clamps on the W-rail to keep the skin from sliding. See Fig. 3

7. Insert ribs 1, 2, and 3 inside the skin and drill 3/32" & cleco the front skin to the ribs. This is my 1st use of the inexpensive 3/32" ($0.25) 3/32" drill bits from Harbor Freight in place of the ~$1.65 #40 bits from ZAC. The HF bits drill fine and the #40 clecoes fit OK in the holes.

8. Turn the aileron upside down so that the front skin was on the W-rail with the outboard-forward edge 13-mm higher than the trailing edge. With the skin was upside down, it was convenient to use spring clamps to secure the hinge flap to the W-rail.

9. Drill 3/32" & cleco the bottom skin to rib 3 proceeding from the forward edge rearward; repeat for ribs 2, and 1.
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Aileron control horns

Aileron control horns

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Hole pattern in L aileron tip rib web

Hole pattern in L aileron tip rib web

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