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Date:  12-8-2013
Number of Hours:  6.00
Manual Reference:  
Brief Description:  

Started out today pretty easily, and finished placing nutplates for the flap hinge access panels. Then, with the aileron spar reinforcing cured, I mounted the aileron hinges, by drilling out the bolt holes, and then installing the appropriate nutplates. The manual suggested that direct mounting of the nutplates would be problematic, due to lack of space for drilling, countersinking, etc,, but that just proved to be a bit of a fiddle, not a huge problem. So last night's six bid layup for nutplate mounting plates proved unnecessary.

After mounting, it became clear that, as the manual suggested, the three layer duct tape placed on the hinges was thicker than the two bid reinforcement. The book says simply to move the alieron forward to compensate, but when I did that, of course the carefully set .05 inch gap all but disappeared. Rather than sand out the wing trailing edge, I'm going to make some two bid spacers to place between the hinges and the spar.

This afternoon I decided to trial fit the lower aileron skin. I've learned to work a bit ahead of the manual, at least with trial fitting, mockups, etc. That minimizes suprises later. This was a good decision for the aileron skin, because there was rather major interference between the forward part of the lower skin and the aft ends of the wing ribs. Also, there is a vertical piece of the lower skin, at the outboard end of the flap section, that was a complete interference with the aileron. So off it went, to be placed about 1/2 inch inboard later. After a great deal of sanding, fitting, sanding, fitting, etc. I got the alieron to fit well enough to allow the minimum 13 degree down travel. There's quite a bit more work to do here, but there is progress.
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Mounted upper aileron skin

Mounted upper aileron skin

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Left aileron, mocked up to check downward travel

Left aileron, mocked up to check downward travel

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