Aileron and Flap Hinge Positions

With the wings now safely located in our garage we used them to locate the position of the hinges and bellcranks on the Ailerons and flaps.  The location of wing ribs 1,2,4,5, 7, and 9 were used to locate the hinge and bellcranks.  Wood strips were clamped to the wing top and the Aileron and Flap were placed in their correct position.  A 1/4" spacer was placed between the aileron and flap to maintain the correct spacing. The aileron/flap pair was then centered on the wing with equal overhang on both ends.  Once centered, the location of ribs 1,2,4,5,7 and 9 were transferred to the aileron/flap spars. Hours: 2

Wing Transport

We were at the point where we needed to have access to the wings to continue.  The wings were being stored at the airport, so we carefully loaded them up and secured them in the trailer (each wing is held in a sling, and the frame is screwed down to the base of the trailer).  The wings were towed back home and are now in the garage.  So the garage just got even smaller.  Hours: 2

Two wings successfully made the trip home

Aileron & Flaps: Hinges and Bellcrank prep

Spent a few hours preparing hinges and bellcranks for attachment to the ailerons and flaps.  This included careful locating, marking, drilling, and deburring a plethora of holes in these parts for the rivets.  There are 5 holes in each hinge, and 10 in each bellcrank.  With all the hinges (8 total) and bellcranks (4 total), this came out to a grand total of 80 holes.  Each hole was upsized to 1/8 inch per the manual.  We also reamed out a 5/16" hole in the bellcranks for a brass bushing insert, and cleaned out the powder-coat paint from the inside mating surface of the hinges and bellcranks.  Hours: 3.5

Michael is reaming a hole for a brass bushing

4 bellcranks and 2 hinges prepared and ready to go

Final Aileron/Flap Tailing Edge Installation

The inside of the aluminum trailing edge was sanded with 100 grit emory cloth to allow a good surface for the Hysol epoxy to attach.  Only the area around the attach point was sanded.  Then, all the surfaces were wiped down with Acetone for a final cleaning.

The two part Hysol epoxy was mixed and applied to the trailing edge of the rib cap strips.  The trailing edge aluminum was re-applied and flush rivets were pulled. 

Epoxy applied and attaching trailing edge

Trailing edge riveted and epoxied in place

The epoxy was allowed to cure for about 30 minutes and then using a finger dipped in water it was smoothed for a nice clean finish.  Hours: 2.5

Smoothed Hysol Epoxy