Brief Description: Outboard Aileron Hinge Error and Fix 1
As mentioned in a prior log, I had to rebuild all of my aileron hinges since the Al. angle used was less than 90 degrees and caused the hinge to "teeter-totter" on the rear spar which was unacceptable. The fix went just fine on the left wing, but I made an error on the right wing. The outboard aileron hinge is supposed to use 1.25 X 1.25 angle so that the rivet line to the rear spar clears the outboard rib aft flange.
Well, I got the fix correct on the left wing, but accidentally used 3/4 X 3/4 angle on the right wing. I didn't realize this error until everything had been drilled to the rear spar. The mistake became obious when I removed the skin to inpect the install and found that the rivet line did not clear the rib flange.
My fix is to fabricate some 0.032 2024-T3 sheet into a doubler that will attach at all the aileron hinge rivet points and back-up the existing spar doubler.
I spoke to Vans and as a result made some changes to my fix. In addition to adding the doubler, they suggested I put the larger angle back onto the aileron hinge. I removed the 3/4 X 3/4 angle and replaced it with 1 X 1.25 angle. I added a second row of rivets offset from the fist. See picture 3.
This is what the rivet line is supposed to look like 1 row for the rib and a 2nd for the hinge
This is what happened when the 3/4 X 3/4 angle was use by accident.
