The pulley bracket for the left aileron had been previously welded but needed painting, so we prep'd and painted it with an epoxy-based gray primer, then sprayed with a gray top coat. The finished part is shown in the image below. Two additional fabric-backing plates were created for the left wing (also shown in the picture).
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| Fabric backing plates and pulley bracket |
Lastly, in order to get the cable to line up properly between the pulley and the aileron bellcrank, we put a "joggle" in the aileron bellcrank. We got this idea based on suggestions from posters in the Wings Forum. To bend the part, we first covered it in tape to protect the finish, then used vice grips to hold the base while bending the other section with a set of locking sheet-metal pliers. Total deviation is approximately 4 to 5 mm. The joggle can be seen in the image below. Hours: 2.0
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| Aileron bellcrank with joggle |
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