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Michaels Web Site
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Date: 5-29-2011
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Number of Hours: 3.75
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Manual Reference:
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Brief Description: RIGHT Aileron construction
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- I reshaped the fat end of the aileron tip rib to get it to fit. I had to also cut off a little over 1/4" off the pionty end, to get it to fit within the bend of the trailing edge of the skin.
- When trying to place the tip rib to mark for drilling, it just falls inside the aileron due to it's inward angle. So I attached a couple of pieces of duct tape (photo #1) so I could pull it into place. I pulled while aligning the red lines on the rib flange, with the pilot holes in the skin.
- I marked the first and last holes on the rib, took the rib out, pilot drilled those two holes, then cleco'd the rib in place.
- Flipped the aileron over and did the same thing to the other flange of the rib, cleco'ing in place after making the two pilot holes.
- With the rib cleco'd in place I then drilled the pilot holes for the rest of the holes in the rib (including the 3 on the face with the counter ballance protruding.
- Tthen updrilled to final size.
NOTE: I did not drill any of the holes along the thin flange of the aileron SKIN, since the hinge needs to be located, and that will determine the hole locations.
- In photo #3 you can see the hing being laid out. As I've done in the past I used double sided tape (about 6 little patches) to hold the hinge in place. The tape allows tweaking the alignment of the hinge to make sure it's perfectly staight, and at the correct offset.
- Per the plans there is an offset for the hinge. My measuring stick is just the right thickness for this, so I took the clecos out of the top surface of the aileron, put that aileron surface on the work table.
- Weighted down the aileron (no clecos holding in place; plus needed aileron skin to be perfectly flat against the work table).
- Put the measuring stick on the table and against the aileron.
- Tweaked the hinge until perfectly straight, then pilot drilled with a 1/32" drill bit in several locations.
- Updrilled to pilot hole size and added silver clecos.
- Pilot drilled all the rest of the hinge holes.
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Tape to pull the tip rib into place.
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Everything except the hinge, ready to go.
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My measuring stick is just the right thickness for the hing offset called for on the plans.
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