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Date:  1-26-2019
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Flap Hinge and Aileron Stop Work

Finally decent weather ..

Made two aileron stops from 7/8" Delrin rod.
• Measured the gap required for the inboard hinge bracket, .35”
• Marked the circumference of the rod at a smidge more, used the band saw to cut the rod.
• Repeatedly fitting between the 7/8" washer and aileron bracket, removed a bit of material using the 3M grinding wheel. Repeated for 2nd stop
• Used a 7/8" washer and #19 drill bit to locate the center point on the aileron stop and marked.
• Used the drill press to make a #40 hole, stepping up to #30, then using a unibit to get to 5/16" as needed. Finally used the 5/16" reamer bit to clean the hole in each aileron stop.
• Inserted the aluminum 5/16" OD washer into the Delrin rod.
• Re-installed the inboard AN hardware (AN3-14 bolt, 960 washers, and the new Delrin rod washer. The Delrin rod acts as the aileron stop against the aileron hinge bracket. I have +25 and -15 degrees for aileron deflection.

For the flap,
• Marked the center three hinge loops for the pin, and removed with Dremel cut-off wheel, filing smooth.
• Marked the existing pin and cut into two pieces, bent one end at 90 degrees, and cleaned the cut.
• Inserted the pins from within the flap into the flap hinge, this required holding the flap up as much as possible, using a pair of small vise grip to push the pins into place.
• Measured equal distant points between the hinge rivets on the wing and located two places between existing rivets for the safety wire.
• Drilled #40 two holes on each wing, then deburred both sides.
• Cut the safety wire and pre-twisted using one of the small scrap pin pieces, then installed the wire on the outboard pin, ran the twisted wire through the nearest hole to the underside of the wing, then back into the other hole.
• Safety wired the inboard hinge pin in place.
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Aileron Stops for Inboard Hinge Bracket

Aileron Stops for Inboard Hinge Bracket

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Flap Hinge Pin Safey Wired

Flap Hinge Pin Safey Wired

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Delrin Aileron Stops Installed on Inboard AN3 bolt

Delrin Aileron Stops Installed on Inboard AN3 bolt

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