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Date:  5-28-2011
Number of Hours:  8.00
Manual Reference:  6ZU4
Brief Description:  Continued.: balance arm & piano hinge

Continued.: balance arm & piano hinge

Previous entry, continued:

14) Riveted the top skin to the hinge at alternate holes.
15) Riveted the reinforcing angle to the front of the aileron. The bulbs of the top rivets interfered with the rivet tool. Should have riveted the angle first to the front skin and then to the top skin, or to have placed the front rivets halfway between the top rivets.
16) Completed riveting the top skin to the hinge, as shown in photo 1.
17) After much thought, I decided that I needed to take the aileron apart and reattach the balance arm with AN960L light washers under the bolt head and nut. With the two light washers, ~3 threads, approximately 3/32” protruded from the lock bolt. That meets the spec in Zenair CS #406. Note that AC43-13B requires only 1 thread protruding (p. 7-6), vs. 2 threads for CS #406. To make the change, I proceeded as follows:
18) De-rivet the end cap, and 2 balance arm rivets.
19) De-rivet the top of the next outboard rib.
20) De-rivet the top closure joint and the piano hinge joint.
21) Remove the bolts, replace the washers, replace the bolts, torque to ~30 in-lb (25 in-lb spec + 5 in-lb friction from the lock nut.
22) Cleco the joints back together.
23) Rivet the aileron back together, 1st the ribs, and then the top flange joint and piano hinge joint.
24) I damaged a few rivet holes in the de-rivet process. So, I replaced some A4 rivets with A5's, as well as, added one new A4 where a rivet holes was too large for an A5.
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Aileron w/ piano hinge

Aileron w/ piano hinge

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