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Date:  11-3-2010
Number of Hours:  5.00
Manual Reference:  LAA
Brief Description:  Mod left aileron to accept counter balance

I found a "new," free text editor, notepad++, which I will begin using to type in my task descriptions. I have been using the very nice notepad2 for this. The problem with just typing the task descriptions into Kitlog Pro is that I would occasionally go over the hardwired 2048 character limit, and lose everything beyond the 2048 character limit. The advantage of notepad++ over notepad2 is that notepad++ has a spelling checker, so my spelling should improve :-)

1. Followed Jeff Garrett's published advice to move the balance arm 100-mm inboard so that the weights would not interfere with the wing structure internals. Thus the centerline of the balance arm will be 227-mm outboard from the 3rd aileron rib rivet line instead to the LAA's specified 327.3-mm (Hmm ... I seldom measure to the tenth of a mm). I measured to the centerline at the ends of each rivet line, thus preserving the 87° angle between the ribs and the aileron. Drew the rib rivet lines, exactly 20-mm inboard and outboard of the centerline.

2. Put masking tape on the drill lines and (very) lightly center punched the hole locations. Pilot drilled the holes 3/32".

3. Practiced cutting square holes in a piece of 0.016 scrap. The evolved procedure was:
- Draw the 22-mm square hole in the required location.
- Drill 1/8" hole tangent to each corner and in the center of the drawn square.
- Use a step drill to enlarge the center hole to 3/8".
- Use a hand nibbler to enlarge the center hole to ~1/16" from the drawn square.
- Use a file to enlarge the hole to the drawn square lines, being careful to avoid "squaring" the corners.
- Touch up the corners with a small round file as needed to ensure rounded corners.

4. I cut the 22-mm square hole in the front face of aileron, see figs. 1 & 2.

5. With 20-20 hindsight, it would have been better to position the balance arm just a bit further out so that the rivet holes for the ribs would have matched the existing aileron top skin-aileron flange holes.
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Cutout for balance arm

Cutout for balance arm

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Pilot drilled rivet holes for ribs

Pilot drilled rivet holes for ribs

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