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Date:  1-7-2017
Number of Hours:  0.75
Manual Reference:  
Brief Description:  Trimming Aileron & Flap Hinge Brackets

We got our Aileron & Flap Hinge Brackets back from the metal shop Thursday. We dropped off our sheet of .063 6061 T6 on Wednesday afternoon and they were ready to pick up Thursday morning. They came out great.

The only exception I found was my error. In creating the CAD file for the Flap Bracket, I was off by 2 degrees on the angle of the top end of the bracket. It was 5/64 larger and would not fit into the rib. So, I had to make a jig to hold all the brackets at once and used my disk sander to remove the extra material. Now they fit perfectly and we still have the wiggle room needed to adjust them prior to riveting in place..

We highly recommend converting your bracket patterns to CAD and having them water jet cut. They come out uniform without twist or warp, which can happen when cutting them by hand. They still need all the edges smoothed out and to be polished prior to priming, but that will not be a long process. We now need to complete the installation of the Spar stiffeners in the Right wing and begin Flap & Aileron construction.

We added 3/8" to the end of our brackets to give us room for one extra rivet on the top and bottom. Additionaly, we chose not to have the hinge or rivet holes cut to ensure proper fit of the control surfaces. Once the hinges are riveted in place marking and drilling the hinge points will be easier and more accurate.
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Nicely cut uniform and flat brackets

Nicely cut uniform and flat brackets

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It's amazing how WaterJet cutting works

It's amazing how WaterJet cutting works

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Smooth the edges and polish any scratches and they are ready for priming!

Smooth the edges and polish any scratches and they are ready for priming!

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