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Building Integrity
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Date: 7-16-2013
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Number of Hours: 7.00
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Manual Reference: ch 19
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Brief Description: New Hinge halves...take 2
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So here's the deal, I've lost 2 nights of sleep over this. Here's what happened. I plan on using flush washers under the countsunk screws to hold the control surfaces on. Not a problem, however, the #10 Washers are line .75" in diameter. This meant that in order to install them without overhanging the trailing edge meant drilling the skin 1/8"-1-4" further back than the plans calls for. BAD IDEA. After installing all the hinges that I had made, I pressed on the aileron hinge to check for play when loads are present. WELL WELL, there was just enough give in the metal to make me think that over time, flexing the hinge half may cause failure. THIS did NOT let me sleep well. I decided it wasn't worth the risk, so Off came all 3 hinge halves and new halves were made. THIS time they were made PER PLANS. In order to deal with the holes now CLOSER to the trailing edge, I will be drilling out the #8 washers for the 10-32 screws. No big deal.
Now in order to drill the new holes I found it much easier to over drill the holes to 1/4" vs 3/8", installed the aileron with loose screws, align the aileron perfectly, then tighten all the screws. THEN, after the aileron was in position and screwed down tightly, I removed Each screw, one at a time, flooded the hole with Flox, then re-installed the screw. After the flox was mostly cured, I then removed the screws, popped the hinge halves off and will let the flox cure completely. After cure I clean up the holes, sand the hinge bed and she will be ready to go.
In picture 3 you will also notice that I sanded down my skim coats with a LONG board "36" and 180 grit in prep for epoxy primer. GREAT news the wing is TOTALLY level. NO visible low/high spots anymore. Now after primer it MAY reveal some more, but that just means a little more sanding. This underside wing is ready to go!!!!!
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no sleep
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sleeping like a baby
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"like a glove!"...ace ventura...
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