Chapter 19 – Ailerons

Chapter 19 – Ailerons

6 June 2013 — Today I started off by Alodining 2 each aileron torque tubes.

For the aileron torque tubes I used 1 meter long PVC pipes capped on one end to Alodine the tubes, and then I simply hung one up to dry and clamped a dowel to the window ledge with the torque tube slid over it for the other one to dry.

Chap 19 - Elevator torque tubeChap 19 - Elevator torque tube AlodinedChap 19 - Elevator torque tube Alodined

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15 June 2013 — I started by marking up a P6 hinge and cut 2 each 8″ lengths & 4 each 6″ lengths out for the ailerons (enough for both wings).  The aileron hinges look offset in the pic below because they are: one side must be reversed because this is how the hinges are mounted to the ailerons & wings.

I also cut out a 4″ length for the rudder (which typically takes the smaller P5 size, so I’ll just trim it down to size).  For now I’ll wait on cutting the rest of the rudder hinges since I don’t have any P5 size hinges on hand, however, since I do have another P6 hinge set on hand I will probably rip it to width, and then cut the lengths out later on.

Chap's 19/20 - Aileron & Rudder HingesChap's 19/20 - Aileron & Rudder Hinges

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16 June 2013 —  I finished up the evening by taking the long aluminum “board” with sandpaper on the edge & giving the Left wing TE and a good sanding.  I also re-checked the measurements & shape of the TE.

I then measured, marked & drew out the aileron outline for planning.

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20 June 2013 —  I started today by pulling the peel ply from the Right wing root LWA7 layup & the aileron control tube channel.

I then razor trimmed the LWA7 BID layup.

I drilled a 1-1/8″ hole to expose the aileron control tube channel in the Left & Right wing roots.  I then used a 1″ sanding drum on a drill & a mini-drum on the Dremel tool to widen the hole diameter to around 1-3/8 inches. . . enough to slide in the aileron control bearings that I picked up from JD Newman at Infinity Aerospace (the same place I got the fighter style stick grips).

Chap 19 - Aileron Wing Root BearingChap 19 - Aileron Wing Root Bearing

I followed the directions JD sent.  First, I covered the main bearing assembly with cling wrap, then cleaned off the Clickbonds with Acetone, and finally roughed up the bottom attach surfaces of the Clickbonds with sandpaper in prep for floxing them on.

I then mixed a whole wopping 6 g’s total of wet flox slurry & mounted the Clickbond/ Bearing assemblies to Left & Right wing roots.  As you can see below I used a large screwdriver through the center hole on each assembly–duct taped in place to each wing–to keep pressure on the aileron bearing assembly, and thus the Clickbonds getting floxed onto the wing root surface.  I then let the flox cure.

Chap 19 - Mounting Aileron BearingChap 19 - Mounting Aileron BearingChap 19 - Mounting Aileron Bearing

 

 

 

 

 

 

 

 

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21 June 2013 — Today I started by finishing up the installations of the Aileron control system bearing that is mounted at the end of the aileron control tube channel that begins (or ends, depending on which way you look at it) in the wing root area. The original plans calls for simply glassing in a phenolic plate with a hole drilled into it to be used as the aileron control system bearing.  This is also what is called out in the plans on the fore & aft ends of the Chapter 16 control system tube that I mounted the brackets for inside the fuselage a week or so back.  Most newer EZ’s that I’ve researched have upgraded to the type of bearings that I’m using here, sold by JD at Infinity Aerospace.  The problem with phenolic is that it eventually wears out a little bit, widening the hole and thus allowing just a bit of slop in the control system.  Of course this slop, even a little bit, isn’t good but can be prevented by installing actual metal control system bearings.

Chap 19 - Aileron wing root bearing

Chap 19 - Aileron wing root bearing

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22 June 2013 — I started today by testing the clearance inside my Right wing root for the Aileron Tube Bellcrank (CS-132) that I purchased from the Cozy Girrrls.  There is a possible clearance issue if not enough foam is removed from the bottom edge of the wing root.  I mounted the the CS-132 to the aileron bellcrank bearing tube (CS-152) and then slid that into the aileron tube bearing assembly that I had just mounted to the wing root via Clickbonds (click here for info from the Cozy Girrrls on Clickbonds).

Chap 19 - Aileron bearing test Chap 19 - Aileron bearing test

Fortunately for me I had measured correctly so I had no clearance issues with my Aileron Tube Bellcrank, and it rotated freely in both directions.

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Recent Posts

Project Update

Hi Folks,

Well, Rough River 2017 is in the history books.  A great Rough River all the way around!  Marco’s new GRT Mini & GNRS480 avionics install went off without a hitch, providing an awesome proof of concept for my upcoming panel.  In addition, the myriad of builder tips that I got from Buly, Rick Hall, James Redmon, Terry Schubert, Mike Beasley, Bruce Sinclair, Bill James and countless others were gold in the bank for so many upcoming component decisions and configurations I need to make.

As I mentioned before, I’ve had to adjust my schedule a bit over the past 6 weeks, which of course impacts my goals.  Yes, I will continue to fight in my hope that this will be the final push to get the main assembly of the aircraft completed.   I do plan on having the main structure of the aircraft finished by year’s end.  An aggressive timeline to be sure, but I think it’s very doable.

I’m still working out the finer details of making everything fit inside the cockpit.  Since the vast majority of what I’m doing are all mods, these usually require a lot of in-house R&D, and then trial & error when finally at the install phase.  However, the curve is exponential in that as each component is designed and installed, it accelerates the build because besides just being in the “done” column, it is one less thing to design and build.  Moreover, it’s a variable that has been changed into a constant.

All this is just to say that even though things seem to be going slowly, there really is a momentum building for this project.  These pesky mini-tasks burn time, but as they are finished and systems are integrated, then when the final airframe components builds are finished, this plane will seriously be close to being done. Again, these mini-tasks are definitely time-consuming and a lot more slow going then planned.  But finishing them now allows me to work all this stuff while I can stand right next to the fuselage without having to deal with strakes, or nose, being in the way!  

I have to say that it’s much easier and more fun to build the big stuff that makes this project look like a plane, and I often feel my discipline waining to go build something “cool”.  So, although obviously not as sexy as seeing major aircraft components (i.e. nose, strakes, canopy) being completed, these mini-tasks are oh so necessary for quality of flying later on!  Moreover, these immediate tasks, in turn, will allow me to finalize the configuration of the nose components. At which point I will focus on the building the nose and the canopy.  . . while concurrently finalizing the wheel pants install (nope, haven’t forgot about those!).

Cheers!

 

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