Aileron/Flap Work

We completed cutting the slots in the leading edge of the two remaining control surfaces.  We also noticed a few places that will need some epoxy touch-up between the false rib and fiberglass leading edge. Hours: 1

Aileron and Flap Work

We sanded the wood cap strips on each of the ailerons and flaps so that there is a "nice" transition between the cap strips and the fiberglass leading edge.  We used various methods to get the "nice" transition, sanding blocks, orbital sander, and Dremel multi-tool.  Once we had the transition correct we started working on opening the area around the hinges and control attach points.  We cut most of the material away using the Dremel multi-tool and then finished using files.  We got 3 of the 4 parts completed before stopping. Hours: 3

Ed sanding the Cap Stip with the Dremel Multi-Tool

Bottom of Flap with Fiberglass Removed from Control Hinge

Top of Flap with Fiberglass Removed from Mounting Hinge

Attaching Flap and Aileron Leading Edges

Leading edge epoxied in place, and held temporarily with tape

Using Hysol epoxy, we attached the remaining false ribs to the right flap.

Then, we cleaned and prepped the aluminum aileron and flap spars, mixed up some more epoxy, and glued all of 4 of the leading edges to their respective flap or aileron (both right and left sides).  There are 6 primary ribs, and 14 false ribs for each piece, so a total of 20 epoxy attach points for each aileron and flap.  Once the epoxy had cured for about 30 minutes, it was smoothed to make nice filets.  Hours: 3.0

More work on leading edge for right aileron & flap

We continued working on the leading edge for the right aileron and flap (similar to what we've already done on the the same parts for the left side).  We filed a few false ribs so that they would fit around the hinges and bell-crank, prepped the fiberglass surface for gluing, and then epoxied 14 false ribs into the leading edge of the right aileron.  After the epoxy had set for about an hour, we smoothed the glue fillets.  We also prepped the right flap for the same procedure, but will epoxy the false ribs into that flap another day.  Hours: 2.5

Right Aileron and Flap False Rib Locations

We marked the location of the false ribs, first on the right flap and then on the right aileron.  This went a lot quick since we had the locations with dimensions written down from the left flap and aileron. Hours: 1.0

Ed Marking Location of Aileron False Ribs

Right aileron and flaps (leading edge) Continued

Ed and I did the final fitting of last leading edge fiberglass piece.  A little sanding here and a little sanding there.  Hours: 1

Right aileron and flaps (leading edge)

After a brief hiatus for summer vacations, plus trying to get other stuff done around the house, we finally got back to working on the ailerons and flaps.  Previously, we had worked on the fiberglass leading edge for the left-side aileron and flaps.  Now we shifted to the same tasks, but on the right-side aileron and flaps.

This is messy work because we are carefully cutting, trimming, and sanding fiberglass.  The picture shows Michael test-fitting the fiberglass leading edge piece onto the aileron, and you can see that gloves and a breathing filter are needed to keep all the fine fiberglass dust from becoming an irritant.   The trimming and fitting takes a bit of time because we have to be careful so that it fits nicely at each rib, and don't want to mess up and trim off too much.  Hours: 2.5

Michael test fitting the fiberglass leading edge onto the aileron

False ribs in leading edge of left flap

Glued false ribs into the left flap leading edge with Hysol epoxy.  The false ribs were secured in place with masking tape, which basically clamped the fiberglass leading edge over the wood ribs.   The Hysol was worked and smoothed to make nice fillets at the base of the ribs after drying about 30 minutes.  Hours: 2.0

Wooden false rib taped and glued

Left Flap Leading Edge

The left flap's fiberglass leading edge was cut to length.  The false rib locations were located using the same methodology as the aileron.  Hours: 1

Left flap & aileron leading edge

Carefully positioned and attached false ribs to the leading edge of the left aileron with Hysol epoxy.  Also began trimming the fiberglass piece for the left flap.  Hours: 2.0

Left Aileron False Nose Ribs

After consulting the Just Aircraft Wings Forum I found a posting that was perfect and even included a drawings of the placement of the false nose ribs.  This was tremendously helpful.  This was discussed in 2011....why oh why hasn't the builder's manual been updated?   The locations were marked on on the leading edge fiberglass and the false ribs were temporarily fit.  Two of the ribs are going to require some custom fitting at the spar due to interference with the hinge brackets.  Hours: 1

False Nose Ribs Locations Marked

Aileron False Nose Ribs

The manual gives the location of the false nose ribs.  But to be honest, it is extremely lacking and confusing.  We were given 54 total false ribs which equates to 14 per Aileron/Flap.  After locating two false ribs around each hinge point (x6) the remaining 8 false ribs were located based on feedback from other builders. Hours: 1

Aileron leading edge prep

Trimmed and fit the fiberglass leading edge for the left aileron.  Picture below shows some sanding that was done to the fiberglass piece to fit it precisely to the aileron.  The ends were also cut to length and sanded so that they match the ends of the aileron.  Hours: 2.5

Michael is sanding the fiberglass leading edge

Aileron and Flap Hinges

The aileron and flap surfaces were slightly abraded and cleaned at the points where the hinges and bell cranks attached.   A layer of Hysol epoxy was then applied to the hinges and bell cranks, and these were then riveted using CCP44 rivets to the flaps and ailerons.  This gets a little messy with excess epoxy squeezing out from under the parts during riveting.  A total of 8 hinges (2 on each aileron and flap), and a total of 4 bellcranks (1 in the middle of each aileron and flap) were attached.  Excess adhesive was wiped away after riveting.  Hours: 2.5

Bellcrank Attached

Hinge Attached

Left Flap with 2 hinges and bellcrank attached

Aileron Flap Work

We continued work on the remaining aileron and flaps by precisely locating (9.5" from trailing edge to hinge point for ailerons and 10" for the flaps) the two hinges and middle bellcrank on the right aileron and both flaps They were clamped in place using worm hose clamps and drilled for rivets. The parts were temporarily cleco'd until the other aileron and flaps are complete  The holes on all four parts were deburred. Hours: 2.5