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Date:  5-8-2018
Number of Hours:  3.80
Manual Reference:  19-10
Brief Description:  Right Aileron alignment/gaps

Weekend off for Wings Over Illawarra airshow, complete hoot, but they are not getting any easier.

Cleco outer and inner hinge to wing, and sand face of Aileron until can rotate the hinge with a hacksaw blade and lie it flat on the leading edge.

Tried to hot glue blocks to lower surface of Wing/Aileron. Doesn't work well.

Taped up hinge face and attempted to hot glue to leading edge of Aileron. but couldn't align and bond fast enough. Tried again with 5-min epoxy, remove the clamps and get to see what the Aileron actually looks like when it moves.

I have the gap set at each end at 0.13" - near the midpoint of the allowed 0.08-0.20". Up Aileron does indeed bind inboard with lower Aileron skin touching upper Wing skin at about 20 degrees. No good. Down Aileron binds outboard, with upper skin of Aileron touching lower Wing skin at about 30 degrees, which is almost acceptable. Both bindings happen at about 1/3 from the leading edge of the Aileron.

Plan: Make gaps 0.15" outboard, removing material from Aileron upper skin and Wing lower skin. Make gaps 0.18" inboard, removing material from Aileron lower skin and Wing upper skin.

Kept at this until gaps are both 0.2" and aileron can go to 20 degrees up and down with minimum gap of 0.08". It works! May still be a stupid idea...
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Staring at Aileron, willing it to tell me what to do next

Staring at Aileron, willing it to tell me what to do next

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Sand off a bit and re-fit

Sand off a bit and re-fit

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...and repeat

...and repeat

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