Ailerons and Flaps

December 22, 2003

For a change of pace, I have decided to build the flaps and ailerons for both wings before proceeding to build the right wing. Here's a picture of the components that make up the flaps and ailerons (main skins not pictured).  I'm going to get as much prepped as possible so I can prime in one or two large batches.

January 7, 2004

Match drilled aileron ribs to counter- balance. The skin is cleco'ed on upside down, but the point is to get the rib spacing proper to match drill to the counterbalance. Assemblies at right.

January 13-15, 2004

I decided to construct a separate table to build the ailerons and flaps. A flat, sturdy table is recommended by Van's to build a flat aileron and flap. At right, I test fit the aileron nose skins.

I also cut all the aileron stiffeners from stock provided. These are similar to the rudder and elevator stiffeners.

January 16-17, 2004

Deburred all aileron stiffeners. These pics show match drilling the stiffeners to the aileron skins. They are drilled into the table and cleco'ed in place. An old hollow door works great.

After match drilling, its on to dimpling the skins and stiffeners. Pretty mundane but necessary stuff.

January 18, 2004

Fabricated the aileron control stops. Cleco'ed the aileron attach bracket assemblies together and match drilled and deburred. These hold the ailerons to the spar. Also fabricated and deburred the flap attach angles shown at right.

January 19, 2004

Deburred holes and edges in the flap attach brackets. Like the aileron brackets, these hold the flaps to the rear spar. I also constructed the aileron/flap fixtures to hold the assemblies while riveting. This is about as far as I can go on the ailerons before I need to prime some of the parts. I am continuing on to the flaps for now.