Brief Description: Aileron/Flap Alignment and fitting
Aileron Fitting.
Fitted whilst wing in the cradle. Fitted aileron - washers as required to get fit. Made wood alignment tool as per plans (photo shows some parallex). Clamp aileron to wood and adjust rod ends to allow bolt to slip into WD-421 and Aileron Jig Tool.
Set Up.
Used 1/4" reamer sat on aileron bracket bolts and clamped to achieve 1/4" gap (DWG 9A) Drew line on flap hinge 3/16" from forward edge to show minimum edge distance (MED)(Blue line in photo). Fitted flap hinge BETWEEN lower skin and brace with mini cleco clamp at each end and aligned the trailing edge with aileron (red line) I then checked to see if MED line was OK - it was bang in middle of skin holes.
Drilled Flap
I drilled through the bottom skin into the hinge BUT ONLY ABOUT 1/3 WAY at the most outboard and inboard holes. Un clamped and final drilled the partial drilled two holes in the hinge. Re-fitted flap with hinge ON TOP of lower skin/brace and clecod the two holes. Drilled and clecod remaining holes and it all came out as well as I could have possibly expected.
