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Date:  12-8-2018
Number of Hours:  1.50
Manual Reference:  
Brief Description:  Valuable leasson learned, AGAIN!

I am writing this the day after the disaster. I spent yesterday (the 8th) installing the aileron hinges to the spar. After clamping them in place, aligning the hinge moment correctly and ensuring that they did not move or misaligned themselves during the fluctuating temperatures we have been having, I began their permanent installation. Drilled all the holes, removed from spar, deburred all surfaces, prepped and cleaned all surfaces, clecoed back in place to check for fit, then mixed and applied the Hysol and riveted them in place. This AM, after arriving back from church I began to inspect the work when it dawned on me, “did I align the hinges with the hinge brackets”?

I could not remember doing it. So, I pulled up all the plastic sheeting I had placed down in preparation for fiberglassing the leading edges, removed the vertical stands and checked the hinge placement in relation to the hinge brackets. NOPE! I missed this step in my rush to complete the control surfaces and get to the hanger with the completed wings.

Lesson - DON'T RUSH. Think and PLAN each step. Never assume. Check and recheck EVERYTHING before you commit to the final work step. This has now turned into not only a costly mistake material wise, it has cost us at least two weeks that we don't have right now because of the holidays and travel plans. Not happy about it but, what can you do but make every correction necessary to make it right. I have already ordered new spar material and will have to purchase new foam to cut and shape. So, the old adage, check, recheck and check again will always apply. We need a BIG sign to hang in the garage.
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Unknowing I installed the outer aileron hinges 1/4 off center!

Unknowing I installed the outer aileron hinges 1/4 off center!

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center hinge is spot on. So what!

center hinge is spot on. So what!

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Filler blank installed in center rib for cross support mounting.

Filler blank installed in center rib for cross support mounting.

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