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Date:  1-5-2020
Number of Hours:  10.10
Manual Reference:  7-10 to 7-11
Brief Description:  Pitot Work and Assembling the Ailerons

I began today working on the pitot system again. I fabricated a bracket to keep the pitot and AOA tubes from interfering with the aileron bellcrank. It is basically an L bracket that attaches to two of the bolts on the bell crank brackets and has two bushings installed to run the lines through.

Then I moved on to the ailerons. The first thing I did was back rivet the stiffeners on to the aileron skins. I then used my 2x8 brake to partially bend the skins. As with the rudder I had to finish the bend with my hand seamer. It came out good. I'm happy with both skins and they both match the plans.

After that I riveted the A-408 reinforcement brackets to the aileron spars. I also riveted on the K1000-3 platenut to each spar assembly.

After that I assembled the aileron with clecoes and match drilled all the holes. I enlarged the bottom holes between the spar and the skins to #30 with a reamer. I then drilled the holes between the skin and the counterbalance to #40 and then enlarged them to #30 with a reamer.

The first aileron this went fine. The second one I broke off a drill bit in one of the holes. I should have stopped there and rotated the counterbalance to give me a new spot to drill but I kept going. I never could get that hole drilled and I ended up messing up a couple of other holes as well. I ordered a new A-802PP skin and counterbalance from Vans and I'll replace those parts.
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