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Date:  5-29-2011
Number of Hours:  3.75
Manual Reference:  
Brief Description:  RIGHT Aileron construction

- 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.

Tape to pull the tip rib into place.

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Everything except the hinge, ready to go.

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.

My measuring stick is just the right thickness for the hing offset called for on the plans.

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