| Ailerons |
| September 17, 2007 |
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| Last time I had just finished riveting these together. Next is drilling the lead. |
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| Clamped everything down real good. Placed drill press on the slowest speed. Used a Colbalt 3/16" drill bit and plenty of BoeLube then went to work. Drilled half way through the lead on one side then flipped it over and finished the hole from the opposite side. Worked very well! |
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| Next came cutting the aileron skins... Not bad once you study.. and I do mean STUDY, the plans before cutting anything! The skins come oversized to begin with.. 40" or so. You need to cut them down to begin with.. I used a bandsaw. |
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| Filing to my line. Make sure you have a straight reference line for all the funky lines you must cut-out next! |
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| The TOP cut-out line drawn and cut with the tin snips. I did take some of the white protective covering off just so I always know EXACTLY where my lines are.. they won't get skewed from filing and stuff. |
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| Flipped it over and made my lines for the BOTOM. Again.. read the plans carefully! |
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| Filing down to the line... after cutting with tin snips. |
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| Sanding pads I got from Harbor Frieght. They help smooth over the edges so you will not cut yourself, and more importantly, they help take out any stress-risers. |
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| Tips are done. Now starting on the cut-out for the Counter-balance assembly. |
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| Drilled out two relief holes and scoring a line between the two holes with a Olfa knife. |
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| Used tin snips to cut the two vertical lines intersecting the relief holes. With the scored line already there, the aluminum just bends up and snaps off at the score. Filed to my line making sure to maintain the radius in the two corners. |
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| Next comes the inboard cut-out. This is for the Drive Plate Assembly. Was not too sure how to cut out this area?? |
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| Went ahead and used my Radio Shack Nibblers. Worked good! Had to file up to the line and maintain the radius in the two corners after cutting. After cutting this out, I realized I read the dimensions wrong and made this cut too long by 10 mm or so.. no big deal though... Not critical. Make sure you read the plans carefully here. The way they present the measurements is a little tricky if your not ready for it. |