Aug 23, 2022     21-9: Right Aileron finish up - (1.2 hours) Category: 21: Aileron

Got the right aileron off the board and back-rivetted the trailing edge. I was a little skeptical while I was riveting it as it seemed to be taking a bow, but once all of the rivet were set it was perfect.

Got it mounted and it seems a little tight to the in board aileron bracket. It was even rubbing a bit, but I pushed the tip of the inboard rib inward and took care of that. Still a little tighter than I'd like. The outboard bracket seems to be slightly bent inward - I may need to give it a whack.

  Aug 21, 2022     21-9 & 21-10: Left aileron done - (1.0 hour)       Category: 21: Aileron

Unclecod the aileron from the board after a few days of tape curing. Back-riveted the double flush trailing edge. Came out really well. The tape method is a success.

Pulled some of the mounting hardware and temporarily mounted to wing. This is done for now. Will permanently mount after the flap gap fairing is installed.

I did realize that I made a mistake, but I think it is just a cosmetic one. The pull rivets on the end rivets are supposed to be CS4-4s and I used LP4-3s. I was looking for those rivet callouts in the plans and couldn't find them. I should have remembered the 120 degree dimple dies though. I ordered some just for these rivets! Oh well, doesn't look bad. I'll probably do the same on the right aileron to match.

8/28: the more I look at it, the left aileron has a slight bow to it. I put it back on the board and sure enough it sits about 3/32” high in the middle. Worse, there seems to b a slight twist. I drilled out about 2/3 of the trailing edge rivets and tried to fix it. With everything drilled out, it was laying flat again. Then I redid the back rivets hoping it would come out better. Put it back on the board, twist is gone but it still bows 1/16” or so. Better but not perfect. Calling it good.

  Aug 20, 2022     21-5 thru 21-9: Right aileron progress - (6.6 hours)       Category: 21: Aileron

My replacement aileron skin arrived so spent time this morning priming it. Also primed the wing flap gap fairings.

Dimpled the skin and backriveted the stiffeners. Then cleco'd the assembly together. Will wait to drill until I have the left one off the door.

8/21: with the left aileron done and off the board, I put in a big day to get the right aileron pretty much finished. Leading edge riveted together, cleco'd the top and bottom skins and drilled the trailing edge, countersunk the wedge, dimpled the skins, riveted the skins to the leading edge and spar, taped the trailing edge wedge and cleco'd everything down to the door. Looks good. Decided to repeat the mistake on the left aileron for consistency.

  Aug 17, 2022     21-8: Left aileron assembly - (2.6 hours)       Category: 21: Aileron

Got the leading edge skin riveted to the spar assembly and installed the blind rivets to the counterweight.

Installed the top skin and cleco'd in place. Had a few that didn't set tight and I was able to drill out and redo. Learned I need to lean the gun slightly toward the edge to keep it tight.

Riveted the end ribs to the spars and then cleco'd the bottom skin in place just to see how it all looked.

8/18: got the bottom skin riveted with no problem. Had to make a little spacer to rivet the three end rivets that sit below the level of the skin. Of course, I mounted it temporarily to the wing just to see how it looks.

Decided to try the tape method. The wedge sticks out slightly past the skin and I was worried about how to align the tape on the wedge so it didn't stick out. Turns out the width of tape is perfect when aligned with the top of the wedge. Got the parts cleaned and applied the tape to both side. Let it sit 20 minutes for an initial cure then cleco'd through the tape every 10th rivet to make sure it was all aligned. Then unclecod the bottom skin and removed the backing from the bottom of the wedge. Pressed it down and cleco'd as I went. Let that sit a little while, then came back and removed the clecos to expose the top of the wedge. Then removed the final backing and squeezed it tight while clecoing every hole. Looks good. I'll let it sit for about three days to cure before riveting.

  Aug 15, 2022     21-6 thru 21-7: Left aileron pre-assembly - (3.3 hours)       Category: 21: Aileron

Finished the backriveting of the bottom skin and started assembly of the left aileron. It all went together easy and I set it up on a very straight door blank that I used to build RC planes on. Laid it flat on the board as described in the plans, but then they say to cleco the trailing edge wedge in place. How to do that with the aileron flat on the board?Decided to use my spare aileron skin to pre-drill holes in the door for the clecos. Then got the aileron back in place and cleco'd through the door skin. Everything looks good and straight.

Drilled the trailing edge using the angled wood block I made long ago for tail feathers. So far so good.

Disassembled everything. I could tell the skin stiffeners were conflicting a bit. I trimmed the ends a little more with snips and filed them smooth.

8/16: got everything dimpled this morning before work. Still not sure about proseal vs tape method.

8/17: countersunk the trailing edge wedge and riveted the spar doubler.

  Aug 14, 2022     21-5: Aileron prime and assembly - (5.0 hours)       Category: 21: Aileron

Very tedious, but got the aileron parts all prepped and primed.

Got all of the stiffeners, ribs and skins dimpled and prepared for assembly. Back-rivetted the top right skin and went to start on the right bottom skin; realized I had two bottom left skins. I had taken my time to correctly identify and make separate top and bottom skins for each but I guess I messed up. Ended up priming and dimpling two left bottom skins. Not worth trying to correct. Ordered a new bottom skin from Van's.

8/15: back-riveted the left top skin.

Purchases: Van's- new bottom aileron skin

  Aug 10, 2022     21-2 to 21-5: Aileron work - (4.0 hours)       Category: 21: Aileron

Primed some aileron parts to pre-assemble brackets. I tied to take advantage of cooler weather as a storm passed but it was very humid and primer did t come out great. Lesson learned.

8/11: cleco'd left aileron together and predrilled the counterbalance holes. Took a minute to figure out what they were trying to have me do, but figured it out eventually. Removed the skin and cleco'd the counterbalance to the ribs and marked the other holes. Then upsized those holes to #27. Realized I'm going to need some new drill bits to get through this stainless steel. Bolted the counterbalance with the correct hardware. Reinstalled the skin and match drilled the leading edge holes in the counterbalance.

8/12: got right aileron to same condition as left. Setting aside for now to get back on tanks.

  Jul 31, 2022     21-2 thru 21-5: Starting on ailerons - (2.5 hours) Category: 21: Aileron

Pulled down the aileron parts and started removing the vinyl. Separated some of the hinge brackets and doublers. Trimmed all of the skin stiffeners and deburred. Separated end ribs and deburred.

Reading ahead a bit, I see they call for 120 degree dimple dies for the CS4 rivets. Ordered one from Aircraft Tool Supply.

8/4: countersunk attach brackets

Purchases: ATS - 120 deg dimple die