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Date:  1-16-2011
Number of Hours:  1.00
Manual Reference:  6ZU4-6
Brief Description:  Revised mod process for right aileron

Right Aileron Mod Process—Hindsight Enhanced

1) Cut the flange for the piano hinge installation
2) Choose the location for the balance arm installation
a) ~227 mm outboard of the 3rd rib, but placed to utilize existing top flange holes
b) Make sure I get the 87° angle correct
3) Mark and drill the holes top and bottom, leave the front holes undrilled for now. I think it will be easier to drill while the aileron is still tightly riveted.
4) Cut the hole for the balance arm
5) Cut the piano hinge to length
6) Clamp and drill the holes to attach the piano hinge to the shortened flange.
7) Cut the L-angle to length, clamp to the piano hinge, and pilot drill to the front of the aileron, except for the holes by the balance arm hole. Leave those for later, after the ribs are positioned
8) Drill out the flange and top rivets
9) Drill out the control horn rivets
10) Cut, fit, and drill the L-angle horn reinforcement doubler
11) Pilot drill the inboard balance arm rib rib through the pilot holes
12) Cleco rib in place, then measure and drill pilot holes for the front rivets
13) Remove the rib, mark and drill to the control arm
14) Clamp and drill inboard rib and balance arm to the outboard rib
15) Drill the outboard rib for the weights.
16) Cleco the inboard rib to the aileron, bolt on the balance arm and outboard rib
17) Pilot drill the outboard rib to the aileron skin, top and bottom. Then drill the front, using the existing #20 holes as the pattern.
18) Drill out the rivets attaching the trim servo
19) Cut the L-angle servo mount doublers, clamp and drill into place
20) Disassemble, deburr, clean, scour, & prime
21) Put the whole mess back together.
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