Science

Aileron Hinges

The ailerons came built in the kit. They are cut from the wing but the aileron cut out for the wing must be enlarged to allow installation and movement. Two 6" and one 4" hinge is used to mount the hinge to the wing.

Measure and mark the location of each hinge on the aileron.  The aileron the hinges must be disassemble and reassembled with one side flipped over.  Mark and drill holes on the inside section of the hinge as shown. Place hinge flush on the angled section of the aileron with the top of the hinge flush with the top of the aileron.  Drill through first hole at one end of the hinge and into the aileron.  Place a cleco in the first hole.  Line up the other side and drill and place cleco in the hole to keep it aligned.  Finish drilling all the holes for each hinge.  Sand the backside of the pre-drilled halves of the hinges.  Glue the hinge in place by applying a thin layer of Aero-poxy mixed with cabosile and flox on the aileron and hinge surface.  Make sure no epoxy gets into the hinge mechanism.  Rivet hinges in place the same way you drilled and clecoed. Start on outside holes then move in. Clean off excess epoxy and let cure.

Ailerons

 Now place the aileron into the aileron well.  Mark the exact location of each hinge onto the wing.  Cut out a 1/8" notch with the hacksaw blade for each of the aileron hinges on the marks made.  Place the aileron in the well again and drill through the pre-drilled holes in the hinges from inside the well.  Drill one at a time from the ends to the center placing clecos in each hole before drilling he next.  Now repeat the process on the hinge at the other end of the aileron. Finish with the center.  Remove Aileron drill the 1/8" holes in the top of the hinges to 3/16" and attach nut plates to the bottom side.  Trim off the bottom aileron well skin till there is 1/8" gap for the aileron weight to clear. Sand edges strait for aileron and the well with a 3ft long block and 80 grit paper. Attach the ailerons to wings.Check for proper clearance and free movement. Travel for up and down aileron must be 2.5" and is measured from the aft edge of the wing to the atf edge of the aileron. In my case the weight at the front of the aileron was hitting the inside of the aileron well. How do you fix that? I had to cut the well deeper then reglass it.