Brief Description: Aileron Boots to Seal Fuselage Opening
Aileron control tube boot covers keep cold air, moisture out of fuselage which makes for happy wife and pilot. An old plan for handmade boots was perfect. I had surplus Sunbrella fabric (waterproof and windproof) which is pliable enough to move back and forth with ease. Actual fabric size needs to be 9 x 11.5 to account for the greater than 90 degree cut and 9 inch radius. Marked and cut four boots. (2 spares in case I screw it up.) They basically get marked 3/4 inch in on three sides. The longest edge gets relief cuts every 3/4 inch almost up to the 3/4 indented line. That allows the circle to be made without a bunch of stress on the material. The clamping ring is made of .025 alum sheet. Outer diameter is 5.325 inches. Inner diameter is 4.25 inches. I made the inside a little wider than plan to give material more movement without stress. Mine are 4.4 inches inside diameter. Tested how it would come together and took it all home to sew and glue.
Old (1995) plan, but still easy and effective.
Primed and painted two clamping rings.
Tested how it comes together before sewing and gluing.
