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Johns Web Site
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Date: 7-3-2015
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Number of Hours: 1.00
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Manual Reference:
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Brief Description: Ailerons - Tightening The Aileron Skin Flange
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As I started preparation to install the aileron ribs in the aileron skins, I noticed that short skin flange extending from the top of the skin was about 3 to 5 degrees out of parallel with the skin on the forward face of the aileron. This condition is noted in the Builder’s Manual, with the advice to bend the flange slightly to prevent the upper skin from bulging between the ribs. My largest sheet metal brake is only 36-inches long, and the ailerons are 59+ inches, so I had to find another way.
I started with a 2-1/2” long piece of 2X4, and with my bandsaw cut a slot at a 60-degree angle from the bottom, and 5/8” deep. I also cut a relief starting about ¼” behind the slot, at a 30-degree angle from the bottom. The short flange is positioned into the 60-degree slot until it bottoms out, then while applying firm downward force, the top of the tool is forced back until the rear surface of the tool bottoms against the forward face of the skin. This overbends the short flange enough that when it springs back, it is parallel with the aileron front face.
Since the tool is 2-1/2” wide, I moved the tool two inches after each bend, providing a ½” overlap. I controlled the overlap by making marks on the face of the short flange every two inches.
This process worked better than I expected, but if I were doing it again, I would probably lengthen the tool to five inches.
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Flange Bending Tool End View
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Tool in Position Ready to Bend
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Tool Bottomed Against the Forward Skin Face
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