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Kurt Haller RV-9A
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Date:  9-2-2018
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Continue right aileron re-build

Turned on the compressor getting ready to rivet top aileron skin to spar (image 1) and the power strip blew out. Breaker no worky no more...hmm, 15 A compressor, 15 A power strip, not pretty good. Ran out to Lowes and got a 1:3 outlet increaser and a new power strip. Now compressor (and refrigerator) are plugged in directly to the 20A dual outlet. Power strip on the second of three increased outlets.

Riveted top skin to spar. Callout was -3.5, but a good shop head couldn't form unless I upped it to -4, due to the previously riveted (and thereby slightly expanded) holes. Had a few clinchers along the row. Once drilled out, I tried -4's again slightly pre-expanded with the hand squeezer--they all drove fine the second time (image 2).

Used the bottom skin to match drill every 6th hole along the T.E. to hardware store 1/8x3/4 Al angle. Clecoed the AEX wedge to the angle, and match drilled the remaining holes. The holes in the Al angle piloted the countersink, especially on the second side of the wedge.

Clecoed the skins and wedge to the holes in the table made when I drilled the wedge. Everything nice and flat. Marked the excess wedge, de-clecoed, cut off the excess with a Dremel cut-off wheel and filed to the line. Clecoed everything, including the hardware store angle, together (image 3). Haven't decided whether to glue the skins and TE together before riveting. Instructions don't call for it, but it won't hurt to do so. Used pro-seal on the original aileron TE's...thinking about using epoxy this time around...less smell, shorter cure.
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Ready for skins to spar riveting

Ready for skins to spar riveting

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Top rivets all done...some twice

Top rivets all done...some twice

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Ribs and trailing edge left to go.

Ribs and trailing edge left to go.

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