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Kurt Haller RV-9A
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Date: 8-31-2018
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Number of Hours: 8.30
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Manual Reference:
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Brief Description: Aileron rebuild
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Total hours are for 31 Aug and 1 Sep 2018.
Got new top and bottom aileron skins and new AEX wedge from Van's on Thursday. Took Friday off, and fininish de-riveting all 14 of the original stiffiners from their skins. Was ready to rivet the old stiffeners to the new skins when the plastic snout of the back rivet set cracked up completely. Took it home a turned a new steel snout on the lathe. Goos as--no, better than--new. (Image 1)
Got all the stiffeners reattached. Didn't have enough AN426-3-3 rivets, but -3.5's drove ok. Oh the weight penalty! Clecoed up the skins, shown in images 2 and 3.
On Saturday, 1 Sep, 2018, mad a caul from plywood the covers the top skin just inside the ribs clecos. After putting 2 "keeper" rivets in each end rib, the aileron with caul on top was cinched down with a ratcheting tie-down web, making the trailing edge nice and flat. Match-drilled the top skin trailing edge to AEX wedge to bottom skin to the table beneath, clecoing as I went. Used a small piece of Al sheet bent to 5.5 degrees to drill more-or-less perpendicular to the aileron chord.
Vacuumed up the swarf and unclecoed the skins. Deburred the newly drilled holes and dimpled them.
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Refurbished back-rivet set
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New right aileron skins...
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...stiffened with old stiffeners.
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