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Kurt Haller RV-9A
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Date:  10-13-2007
Number of Hours:  12.50
Manual Reference:  7
Brief Description:  Right aileron

Drilled the right aileron to the skelton following same procedures as for the left aileron. Then another screw-up: lifted off all the weights from the backside and the aileron fell off the edge of the table. Brunt of the fall was taken by the leading cleco fom the LE on the OB end--nearly punched through a circular hole in the nose skin and the tab beneath. Both nose skin and tab were cracked. Only other damage were minor dents in the top and bottom skins.

Spent most of the long day devising a repair for the damage. Cut off the damaged nose rib tab and made a new one rib from .040 Alclad. (Images 1 and 2).

For the nose skin, after nibbling out the damage (drilled #30 holes for the corners, then smoothed the edge of course), decided to make a doubler from 0.016 Al (about 2" wide and length that goes from the spar to the ctrwt tube junction with the skin). Image 3 shows the doubler plate in place--will fill in the gap with epoxy filler later, leaving the skin smooth and no one the wiser once it's painted.

I sanded the three remaining original tabs on the nose rib down from .040 to ~0.026-0.028 to accomodate the extra 0.016 skin. Should have been a 0.024, but I wanted to leave it as thick as possible. Can't see and bumps in the reassembled aileron, so took it apart again and now ready to deburr/dimple/spot prime in prep for final assy.

(The new tab, btw, was fitted in assembly so it's still a full 0.040 thick).
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New tab for OB nose rib

New tab for OB nose rib

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OB nose rib from the other side

OB nose rib from the other side

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Doubler in place on nose skin

Doubler in place on nose skin

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