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Date:  4-24-2018
Number of Hours:  5.00
Manual Reference:  19-11
Brief Description:  Aileron control hardware

Tried out all the Aileron hardware, to figger out how to install it all. Note the CG Products CS132R has 3/16" holes, as shown in the plans, but it should be 1/4". Clearance issues abound, and it is difficult to get one's head around what seems like a fairly simple paragraph in the plans.

Step 11 says CS151 should sit 1/4" from the wing rib, (which the plans CS-150 phenolic block is stuck to), but page 15 shows it sitting 0.55" from the rib!

Step 4 says cut the block 6" thick at the leading edge to form the pocket I'm playing in now, but the diagram on page 15 shows the pocket 6.55" deep. This means the pushrod clearance shown as 0.4" with CS127 centrally located is less than 0.25"

The required AN970-4 (vice the plans -3) carves a deep furrow in the foam. Dished out the foam until it doesn't. [Timewarp: I have since learnt that others have noticed this, and anywhere there is a clearance issue actually use an AN970-3 drilled out to 1/4". This is large enough to retain the bearing, the larger -4 flange is not structurally required, as it would be if bolting together the wood components it is specified for.]

After much ruling of lines and armwaving, complete the CS132R bearing plate from 0.032" 2024-T6 with 2 x K1000-4 nutplates attached. Fit this to the foam with 5-min flox, at a position to allow CS151 to sit 1/2" from the inboard surface of the rib, and CS132R to sit 0.55" above it. My "correct" length CS-129 is now looking a fraction long, CS132R is not sitting at 90 degrees like the other bellcrank is.

Have the idea that some peel ply in the glass-to-glass bits here would make life easier. One skin to go for this.
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Supposed to look like........ this!~

Supposed to look like........ this!~

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NQR

NQR

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5-min floxing in bearing plate

5-min floxing in bearing plate

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