Apr 30, 2024     Delay in installing Aileron push rods - (12 hours)       Category: Wings

Not only is the depiction of the aileron push rod fasteners and bearings inconsistent, but it's missing parts and clear instructions.

I spent days racking my brain on how to resolve this. So I went to EAA CHAPTER 1250 INC and asked the experts. They gave me enough to resolve the problem in that the flanged sintered bronze flanged and thrust bearings supplied with a kit was too short to fit in the rod end, so I had to manufacture a small bushing to take up the slack in the rod end.

This has halted the project for weeks. The photo shows a solution that will provide adequate bearing surface using centered bronze bearings.

These bearings will be soaked with turbine oil prior to installation. I'm using turbine oil because Symmco recommends saturating the bearings in R&O 100 turbine oil.

  Apr 10, 2024     Drilled holes left aileron wing hinge.       Category: Wings

Drilled holes left aileron wing hinge.

  Apr 08, 2024     Aileron Hinge Drilling - (1 hour) Category: Wings

Continued drilling left hinge, using clamps to hold it in position.

  Apr 05, 2024     Positioned left aileron on wing - (4 hours) Category: Wings

Progress:
- Riveted right aileron 118 places
- Final positioning of left aileron wing hinge, held on with 20 clamps
- Drilled 15 pilot holes. 103 to go

  Apr 01, 2024     Drilled right aileron wing hinge - (2 hours)       Category: Wings

Right Aileron work completed:
- Drilled and installed one cotter on inner hinge
- Cut one 19.5 inch hinge pin
- Drilled and clecoed 1/8 holes in wing hinge
- Re-checked hole location for outer hinge cotter pin

  Mar 26, 2024     Located holes for right aileron hinge cotter pin - (2 hours) Category: Wings

Located two holes by:
- Studying the drawings
- Understanding the design
- Measuring the angles
- Marking the hinge

  Mar 24, 2024     Aileron right hinge mated - (4 hours)       Category: Wings

Aligned, mated and drilled right aileron wing hinge. Clecoed and mated the aileron and installed pin for a trial fit. Works well so far.

  Mar 23, 2024     Aileron push rods and wing hinge - (5 hours)       Category: Wings

Getting ready to drill the right aileron hinge by:

Locating the drawings and understanding the correct dimensions
Measuring and cutting the wing hinges
Drawing locator marks on the wing hinge and wing
Clamping it in place.

  Mar 22, 2024     Ailerons Done - (8 hours)       Category: Wings

Completed riveting both ailerons. This included a lot of drilling, clecoing, deburring, cleaning, reassembling, re-clecoing and riveting.

The results are strong and light. The light in the photo amplifies the fact the skin is dimpled where the ribs are riveted. For future reference, I would have, just to be sure measured and adjusted the bend angle of the ribs with a sheet metal tool and a square.

  Mar 14, 2024     Ailerons getting done - (2 hours) Category: Wings

Left aileron complete, including drilling and riveting. Right aileron 70% drilled, including hinge.