Ailerons

Tonight I rigged both ailerons using a piece of long cartonboard with a straight line drawn on it.

I torqued the left wing bellcrank as it can stay where it is. I'll wait with torquing the right wing bellcrank as I ordered the Dynon A/P roll servo yesterday (it was shipped today). This servo will be mounted using the bellcrank brackets.

Installed the aileron bellcranks in the wings and temporarily mounted the right aileron and pushrods. Looks cool! But getting all the washers in is definitely not for the faint of heart :-)

After a two week Europe trip for business is felt good to spent some time in the shop again. I finished the short and long aileron pushrods and screwed in all of the rod end bearings.

Riveted both ailerons together and torqued the brackets on the ailerons.

Had to put them on the wings of course :-)

Adriana came help tonight to rivet the top of the ailerons. That definitely was a much easier job for two pairs of hands. We also blind riveted the counterweight to the leading edge while keeping the ailerons on a flat table.

Also cut the pushrods for the inside of the wings to length and sanded the large tubes.

Managed to do some work on my mam's birthday :-) Countersunk and primed the counterweights and also put a layer of primer on the inside of the leading edge skins (it's mating with steel after all).

Using the bending brake, a couple of 2x4's and some duct tape, I taped the counterweights on top of the structure and laid the skins over them for dimpling with hammer and C-frame part. I managed to put some really tiny dents in the skin, but I doubt that you will see these when the blind rivets are in place.

Then blind-riveted the leading edge ribs to the counterweights and riveted them to the spar with an470ad4-5's.

The last step before riveting can start was deburring and dimpling the trailing edge skins and cleco'ing them top side on the spar. The bottom side will stay open for now for easy access to the inside. I thought that the tank stand might help keep this thing stable for riveting.

I'll keep riveting for tomorrow or the weekend, but tried out some to see what the skin access is like. Edges are fine by myself but for the center part I will definitely need some help.

And yes, tomorrow the fuse kit will be delivered!!

Lots of deburring and dimpling of leading edge skins tonight. Dimpled and primed all the ribs and spars and primed the reinforcement plates. Made a stupid mistake with the left inboard reinforcement plate: I riveted it on the wrong way around. How did I notice? Suddenly the most right center two holes were suddenly not lined up anymore! Instead of drilling out the rivets I decided just to redrill the holes. The bolt holes did line up and since these keep the structure together I think this will work out fine.

Short night in the shop today and mainly deburred and scotch-brited ribs.

Match-drilled both the leading edge and rear skins to the ribs and spars for both the left and right aileron. Drilled #30 holes in the counterweight pipe, both in the leading edge and through the tab in the leading edge ribs.

Tomorrow will be deburring, alu-etching and priming time!

Edge deburred the spars and 408 reinforcement plates. Match-drilled the 408 reinforcement plates to the spar. Enlarged the holes for the aileron brackets to #12. Clecod the side ribs and rear skin on the right spar.

Yeah! I passed the 400h mark on my 7A today! Let's party :-)

Today I finished deburring the right stiffeners on the scotch-brite wheel and match-drilled them to the left rear aileron skin. After dimpling, alumi-prepping and priming the stiffeners and edge-deburring and dimpling the skins I back-riveted 16 of them to the left skin and the other 16 to the right skin. Came out pretty well and this re-affirmed that back-riveting is such an easy thing to do!

After that I bend both aileron skins in my home-made bending tool (made from two hinged 2x10's).

Clecod together the aileron leading edges with the side ribs and counter weight pipes.

Started work on the ailerons tonight and cut all the stiffeners to length and deburred 16 of them for the left aileron. Clecod them to the rear skin and match-drilled all the holes.