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Kupe's Zodiac 650B
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Date: 4-21-2013
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Number of Hours: 2.50
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Manual Reference: 6-PH-1
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Brief Description: Right Aileron Piano Hinge
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Converted the right aileron from a flex hinge version to a piano hinge version like I had previously done with the left aileron. Picking up from yesterday, I drilled out the L angle I had fabricated and clecoed it to the top forward face of the aileron by pushing the clecoes out from inside the aileron. Clecoing from the inside left me room to use the L angle as a straight edge for my Olfa knife cuts.
Once the L angle was secure, I removed the rest of the top-side clecoes so that I could flip the aileron onto its top thus placing the excess top skin on a flat surface for cutting. Scoring the excess top skin with the Olfa knife, I was able to remove the entire 30mm excess in 1 piece using only 12 scoring stokes with the knife. The cuts it makes are straight and clean.
I finished the newly cut edge with a file, flipped the aileron back right-side-up, laid out a new rivet line (to match the existing top skin line), drilled the pilot holes in the new rivet line, inserted the piano hinge between the L angle and the newly cut skin and match-drilled the hinge with the new rivet line. When finished, I removed the hinge to trim it to size and to match the angle of the outboard skin. Everything was routine and turned out well.
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Upside-down aileron with L angle clecoed from inside ready for cutting. Note the Olfa knife.
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After the cut: a single 1537mm x 30mm piece after 12 strokes with the Olfa knife.
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The hinge in place, trimmed, drilled out, and clecoed.
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