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Keiths Web Site
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Date: 8-6-2009
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Number of Hours: 3.00
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Manual Reference: P 18-02 Step 2
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Brief Description: Redo flaperon pivot brackets
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Vans had sent me a replacement piece of AEX as the original piece was too short. The replacement was the same length (7.5 inches) so I took the opportunity to fabricate 3 new brackets and complete the work on one of the originals that I had not been happy with. Note, if you remove material for lightening, you need to make allowances for grinding smooth the cut you have made. If you mark, then cut, close to the one inch dimension, it is very easy to make the part undersized once you have finished grinding the edge smooth. By the way, I weighted the part removed. We are talking here of 20 grams saved across all 4 brackets. Not worth the effort, and risk. (Note: the accurate location of the hole (top left) is important. It determines alignment of the rod end bearing with the bracket in the wing rear spar).
Armed with my new engineering drills I was able to select a 21/64 drill to enlarge the hole prior to tapping. Others had commented on the difficulty of getting the enlarged hole concentric with the pilot hole, so I devised a rough-and-ready drilling jig. See Picture 1. You can see I have taped the drill bit so that I stop drilling after an inch, as per the plan. There's no significance in the yellow colour of one of the wood scraps ;-)
Holes drilled, I tapped them using the same jig in the vice with a spot of tapping fluid. Picture 2.
Picture 3 shows the three new completed parts. There's also a fourth from the earlier batch, not shown.
Tim, my inspector, arrived this evening. With a lot of shuffling about, I managed to produce for him two wing skeletons, the tailcone, the rudder, and the tailplane, all of which he blessed. We discussed the flaperon actuating bracket, Page 18-05 Step 1, as he was less than happy with the three solid rivets which are too close to the angle of the bracket. Experienced by others, on the internet. Further research required.
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Drill jig for pivot brackets
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Tapping pivot brackets
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New parts ready
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