This morning I measured, drilled out, and constructed the right aileron balance bar assembly. This is a challenging job because so many separate measurements have to come together between 4 distinct and opposing parts: The aileron skin, the balance bar, and 2 independent ribs. Add to that the small hole in the front of the aileron skin for the bar to protrude through. Finally, the whole assembly is put together inside the aileron which makes clecoing and riveting a challenge.
Once again with a lot of careful measuring and remeasuring and a little dremel trimming of the opening, the whole section went together nicely and fit inside the aileron like a glove.
Afterward I updrilled everything to final size (mostly A4 rivet) and then I disassembled the entire aileron in preparation for cleanup.
A test assembly of the balance bar section. The bar extends at a 94 degree angle from the aileron.
The results after wresting, trimming and wrestling some more inside the aileron skin.
Front view. The extension will carry counterweights and fit inside the wing.
