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Date:  8-4-2018
Number of Hours:  4.00
Manual Reference:  19-10
Brief Description:  Left Aileron installation

Trimmed upper Aileron cove a bit more.

Hotbox heating bulb had failed again, epoxy at room temperature, (4 degrees C). Noticed whilst visiting Bunnings Aerospace that incadescent bulbs are still available in colored lights, 25W. They are not otherwise available, and the halogen bulbs I have been using are short lived and expensive. Had a brainwave, and bought an extra batten fitting and set up two bulbs in the hotbox, one green, one red. If I look in the box and only see either of these colors I will know. I can blow one bulb, and the other will maintain temperature. Sorted.

Bondo'd hinges to aileron. After cure see it is no bloody good, Doesn't move smoothly and is not oriented right.

Reworked some C clamps to jig the Aileron properly.

Whilst in the mood made a giant C clamp to help with injecting epoxy in the delams on the wing.

Redid fixing the Aileron hinges to the Aileron, using 5-min micro, which I have just invented. Gives me a better working time than stupid Bondo, and will hopefully be removable later...

After cure removed Aileron, (which was aligned correctly this time), and drilled two 1/8" holes in each hinge, popped off the hinges, (which was possible), and cleaned up the 5-min micro.

Refitted the hinges with hardware store rivets in the holes and refitted to Wing. All working well.

Drilled remainder of holes, removed hardware rivets, deburred, cleaned and prep sanded everything.

Fitted hinges with runny flox and rivetted with 14 x BSPQ-43

Tried giant c-clamp on first delam, drilled two small holes, softened with heat gun, injected raw epoxy, covered with peel ply, some paper towel to wick away excess epoxy and clamped with wedges.
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Looks good, but isn't...

Looks good, but isn't...

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Rivetty, rivetty

Rivetty, rivetty

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Clampy, clampy

Clampy, clampy

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