Dec 10, 2021     Aileron Parts Assembly - (2.0 hours)       Category: Ailerons

Riveted and trimmed the trailing edge on the left and right ailerons. They both came out perfectly straight and with virtually no twist (0.2 degrees). THEY ARE COMPLETE!!!

  Dec 09, 2021     Aileron Parts Assembly - (3.5 hours)       Category: Ailerons

The left and right bottom skins were riveted to the spar. The trailing edges were clecoed in place. Then the main ribs were then riveted. The trailing edge was dissembled, cleaned, tape applied and set in place and clecoed. Both ailerons were set aside to let the tape cure. Sounds so simple, but....Actually, it wasn't too bad. No skins were harmed in this process, either the planes or me and the awesome assistants I have - Dean and Paul and yes, there is a lot of DNA floating around in the structure somewhere.

  Dec 08, 2021     Aileron Parts Assembly - (2.5 hours) Category: Ailerons

Riveted the top skins and main ribs to the spar for both left and right ailerons. Note to Builders; The callout for the 3-3.5 skin rivets were slightly off. The better fit were the 3-4 size. Also, consider upping the size for the main ribs to spar rivets.

  Dec 06, 2021     Aileron Parts Assembly - (3.5 hours)       Category: Ailerons

Finished riveting the leading edge to the nose ribs. Laid in the spar and riveted it in place (left and right). Roughed up the underside of the trailing edges of all skins in preparation for the trailing edge installation. Cleaned everything with chemicals then clecoed both top skins to the spar and leading edges. The main ribs are also cleaned in place.

  Dec 05, 2021     Aileron Parts Assembly - (5.0 hours)       Category: Ailerons

Ensured all parts have been deburred. Dimpled every #30 and #40 hole in both ailerons - and there were a hell of a lot of them. That included both leading edges, top, bottom skins, both spars, ribs and any other hole I could find. Clecoed the counterbalances and end ribs into the leading edge and began riveting the ribs to the leading edge.

  Dec 04, 2021     Aileron Parts Assembly - (4.0 hours)       Category: Ailerons

Completed back riveting the remaining 2 ribs to the spar. Assembled both left and right ailerons and inserted the trailing edges between the top and bottom skins. Set the ailerons to level based upon the line between the trailing edge and apex of the trailing edge wedge. I then drilled all the trailing edge holes at the proper angle to the wedge. Marked both edges for cutting, then disassembled the trailing edges and countersunk both sides parallel to the centerline of the wedge, similar to the way I did the flap trailing edges.

  Dec 03, 2021     Aileron Parts Assembly - (3.0 hours)       Category: Ailerons

Finished riveting the aileron skin stiffeners in place, with only two upper ribs left to go. Began installing the left upper skin in place on the spar and under the leading edge skin. Temporarily clecoed the left counterbalance and ribs in place.

  Nov 29, 2021     Aileron Parts Assembly - (4.0 hours)       Category: Ailerons

The aileron skins were dimpled and deburred. The ribs for the left top and bottom skins were riveted in place. The right bottom skin has the rivets in place awaiting rib installation.

  Nov 28, 2021     Aileron Parts Fabrication       Category: Ailerons

I began the day by attaching the counterweights to the nose ribs with the called out hardware. Then I reassembled the leading edges, drilled the holes #40 holes in the counterweights, then enlarged them to #30. Hint - make sure to use sharp drill bits, they may dull rather quickly after going thru that stainless tube. Also, BoeLube was really helpful as aid to the drilling process.

  Nov 27, 2021     Aileron Parts Assembly - (5.5 hours)       Category: Ailerons

I'm trying to do the left and right aileron assembly at the same time, we'll see how that goes. I began the assembly by pulling off the 9 year old blue vinyl, did I mention it's boring to do this, but necessary. There, I vented off and feel better. Deburring the spar and leading edge skin came next. Then I clecoed the nose ribs and doubler to the spar. Helpful hint. Be sure to cleco the parts from the rear of the spar as you have to take the spar and leading edge skin off and on a few times. With that done I inserted the stainless steel counterweight tubes, which were perfectly cut by Van's. Match drilled the nose ribs to the counterweight thru the leading edge skin, removed the spar, then the bottom holes in the nose ribs to the counterweight were drilled. Then the upper rib holes were marked for drilling. I took the counterweights to the drill press and stepped up drilling the holes to final #27 size. Trust me, it helps to carefully mark all the holes in the counterweights so you drill the correct ones. Also mark which nose rib goes to which set of holes. No need to ask me why I recommend that. I deburred the steel tube holes and called it a day.

  Nov 25, 2021     Aileron Parts Fabrication - (1.5 hours)       Category: Ailerons

Short day while waiting for the flap trailing edge adhesive too cure. Riveted the hinge brackets, nut plates and doublers.

  Oct 17, 2021     Aileron Parts Fabrication - (2.0 hours)       Category: Ailerons

Countersunk the holes on the right aileron A-1006-1B Outboard Hinge Bracket. Machine countersunk the #10 Screw holes in the right and left A-1007-1B Inboard Hinge Brackets. Dimpled 120 degree dimples on the A-1005B-1L left angle. However, the callouts on which holes to dimple appear to be in question so some research needs to be done before I do the right one. Both aileron spars were deburred.

  Oct 16, 2021     Aileron Parts Fabrication - (2.5 hours)       Category: Ailerons

Completed rough cutting all of the 32 A-710 Stiffeners. I then sanded all 192, yes 192 edges to their final shape and deburred them. Fun? No. Necessary? yes. Just happy to have this behind me.

  Oct 15, 2021     Aileron Parts Fabrication - (2.5 hours)       Category: Ailerons

Continued fabricating the A-710 stiffeners. Got about 50% of the rough cutting completed.

  Oct 14, 2021     Aileron Parts Fabrication - (1.0 hour) Category: Ailerons

Began fabrication of the A-710 Stiffeners. Final drilled all the #40 holes and began laying out the cut lines and then began cutting a few of the stiffeners from the 8 angles provided.

  Oct 13, 2021     Aileron Parts Fabrication - (1.0 hour)       Category: Ailerons

Although only one hour was logged for tis task, it took a couple of hours to read, reread and understand the instructions and to locate the tools for this and upcoming tasks. Anyway, the left A-1006-1B and the A-1007-1B hinge brackets were machine countersunk. Appears I need some more tools and patience in this area. Good news - Captain Kirk made it into space and at 90 years old. There is still hope I can get there - if only I can cut a good advertising deal so I don't have to pay millions for a 10 minute ride.

  Oct 12, 2021     Aileron Parts Fabrication - (3.5 hours)       Category: Ailerons

The Outboard and Inboard Hinge Brackets were separated and deburred. All of the A-1014/15 Nose Ribs were faceted, deburred and dimpled. All were checked for 90 Degrees and needed no adjustment. These parts were also final drilled and machine countersunk where applicable. the A-1005 main ribs were separated, deburred and dimpled.