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Kupe's Zodiac 650B
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Date: 3-31-2013
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Number of Hours: 3.00
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Manual Reference: 6-W2, 6-W12
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Brief Description: Aileron Horn and Aileron Balance Arm
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Upgrade the aileron by adding the balance arm. The balance arm is an 18 inch-long square aluminum tube that extends out the front of the aileron into the wing to help stabilize the ailerons and reduce flutter. The arm is attached to the aileron by sandwiching it between two additional, tightly-spaced ribs near the outboard end. Adding the balance arm required the addition of a 22mm-square hole in the leading edge of the aileron (same size as the arm itself) and two new rivet lines to hold the new ribs on either side of the square hole. Lots of measuring and re-measuring,a little dremeling, some aligning and drilling and the final result was not bad.
The aileron horn is the connection point between the aileron and the aileron actuator rod which is connected, via push-pull rods and cables, to the control stick in the cockpit. The horn is attached to the aileron on the endboard end, slightly recessed from the end of the wing. The horn starts out as a plain strap of aluminum 1 x 4.25 inches. To that blank stock, you drill 4 rivet holes and a large, 5/16" attachment hole and round off the forward end of the strap to a 12mm radius circle. Then the horn is attached to the aileron by the 4 rivets.
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The two new, tightly-spaced ribs clecoed close to the outboard tip of the left aileron.
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The balance bar extending out the front of the aileron from in between the two new ribs.
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The aileron horn - drilled, rounded, and attached to the inboard end of the aileron.
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