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Bobs Ten
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Date:  1-8-2014
Number of Hours:  0.90
Manual Reference:  24-3.3.4
Brief Description:  Install Left Wingtip

1336 - 1430

Talked to Vans last night about tip misalignment. Although Ken said that it was an unusal problem, the forums say differently. They were happy to help, though, and I was in the process of taking photos to send them when I started studying the wingtip. I clamped the aileron to the flap and set them to full reflex for alignment. Next I removed most of the clecos from the wingtip. The TE was then EASY to allign with the aileron. Further inspection of the match drilled holes with the tip clamped to the aileron verified the cause of the misalignment. Following the plans, I made sure that the wingtip was tight to the skin flange. Clamped in the proper postion, the match drilled holes were off on the top side of the wingtip by about half of the hole diameter. This slight misalignment over the chord distance yieled the tip misalignment.

Knowing now what the issue was, the fix became easy. The tip was clamped in place and the pilot holes were drilled again. I am certainly glad that I match drilled with a #40 drill the first time! The newly drilled holes, when final drilled to #28, all but eliminated the misdrilled holes. As I am using the Click Bond nut plates, any remaing void will be filled with structural epoxy.

This session consisted of match drilling the wingtip again while clamped in place, dimpling the skin for #6 screws, and machine countersinking the holes in the wingtip to accept the skin dimple.

NOTE: WHEN MATCH DRILLING THE WINGTIPS, DO NOT FOLLOW THE PLANS STEP BY STEP, ADD THE FOLLOWING STEPS.

1. Temporarily install flap and aileron.
2. Set flap at reflex position.
3. Match aileron to flap and clamp together.
4. Install wingtip and match Trailing Edge to aileron.
5. Proceed to match drill and cleco wingtip per plans.
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