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Date:  11-11-2017
Number of Hours:  4.50
Manual Reference:  section 5
Brief Description:  Tooling

Since our last entry we have been waiting for new trailing edge to arrive, as well as a new 3 position switch for our foam cutter power supply (USPS is the worst. The last 4 days our switch has been sitting in a trailer somewhere be tween Ocala and Jacksonville. In other words, limbo!).

So, we have been using this time to think out and fabricate some jigs to help us with building and aligning the Ailerons, the hinge brackets and the trailing edge. I came up with a jig to ensure every hinge bracket was extended and aligned correctly (see photo 1.). It took only one try to get it made and just a tiny bit of tweaking to get it right. It made the alignment job so easy.

We also came up with the correct profile for the trailing edge of the Ailerons and Flaps. We made a tool that would open the trailing edge material to the proper gap and ensure the shape would fit the ribs without dipping downward between the ribs once they were installed. When the material showed up yesterday we tried it and it worked perfectly. Now to taper the ribs per the manual for a proper fit. It took six tries to make this tool correctly. Even though we have only used it on one piece of the material so far, it worked like a champ.

Having a one piece trailing edge,instead of the two piece that was supplied with the kit, will be a comfort. For the life of me, other than cheaper shipping by thier supplier, I can't understand the reasoning for shipping short pieces with the kit. Anyway, back to work soon to get some progress made.
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Alignment jig for Aileron Brackets

Alignment jig for Aileron Brackets

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Jig in use. WOrks great!

Jig in use. WOrks great!

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Trailing edge profile correction tool. Worked great as well.

Trailing edge profile correction tool. Worked great as well.

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