Wing/Aileron Construction |
Date: January 2003 |
Chapter: 2.0 Wings |
Section: Wings |
Special Feature - "Mr. Wings goes to the Airport"
Section 2.1 Wing Cores
Pre-2002 - Chapter
2.1.1
- "Joining Leading Edge Wing Cores to Spar"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.1.2
- "Joining Trailing Edge Wing Cores to Spar"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Section 2.2 Wing Skins
Pre-2002 - Chapter
2.2.1
- "Lower Skin"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.2.2
- "Glassing"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.2.3
- "Rudder Conduit Installation"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.2.4
- "Top Wing Skin"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.2.5
- "Wing Trailing Edge Rib"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.2.6
- "Wing Leading Edge Rib"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.2.7
- "Wing Attach Bolt Access Holes"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Section 2.3 Ailerons
Pre-2002 - Chapter
2.3.1
- "Wing Tip Preparation"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.3.2
- "Aileron Cutouts"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.3.3
- "Aileron Wells"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.3.4
- "Glassing Aileron Well and Ribs"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.3.5
- "Aileron Construction"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
Pre-2002 - Chapter
2.3.6
- "Torque Tube and Hinge Backing Plates"
FB
This section was completed by the factory as part of the "Fast Build Wings" option.
January 2003 - Chapter
2.3.7
- "Hinge Installation"
In this section, the first step is to locate and notch the hinge pockets, and remove 1/4" from the wing trailing edge in order for the aileron counterweight to clear during it's travel. The 8" hinge is the most inboard, 5" from the inboard end of the well, and the 2 6" hinge are spaced out 31" center-to-center from here. These hinges are cut from the 6' piano hinge offset (the curve of the two sides are opposite). I went ahead and cut the rudder hinges first since they are not offset, and the pulled the hinge pin and reversed the halves.
Once the hinge pockets are located, they are notched 3/16" deep with a Dremel. I used my 6' straight edge to make sure they were all inline with each other. The pockets are then chamfered to clear the curving portion of the hinge arm, and then 3/16" mounting holes were drilled (2 in the 6" hinges, 3 in the 8" hinge). The hinges were then attached with 3/16" clecos, and the straight edge was clamped to them to check travel. Later the clecos were to be replaced with protruding AN screws, but I elected (after discussing it with the factory) to replace these with counter sunk screws and Tinnerman washers.
Aileron Hinge Fitting
Fitting Aileron
We had one aileron with a significant twist in it. We heated it with a halogen lamp and applied weight to it to straighten the trailing edge off an on for a few nights which eventually worked the twist out.
Fixing Aileron Twist
January 2003 - Chapter
2.3.8
- "Attach Hinge to Aileron"
Once the aileron was fitted in the opening, the hinges were temporarily attached to the aileron by '5 minute' epoxy. The epoxy was applied to the hinge, and the hinge had sponge rubber foam stuffed behind it, so that when the aileron was braced in place, the rubber pushed the hinge against the aileron while the epoxy cured. Next it was checked for interference throughout it's travel, sanding anywhere it rubbed. We had a odd interference, where the foam "tunnel" that the torque tube exits through interfered significantly and had to be sanded out (picture below). Once everything appeared in order, the hinges were attached to the aileron with microglass and rivets (long rivets penetrating the torque tube on the inboard hinge).
Aileron Hinge Attachment
Next the torque tube was attached with bolts and rivets to the aileron, which will be later attached to the control cables through a bell crank on the inboard end of the wing inside of the engine cowling. Also, we've decided to go with the flush-head screws with tinnerman washers to spread the load out.
Aileron Control Torque Tube on Wing Inboard Bulkhead
Counter-sunk Mounting Screws
Nutplates installed to Replace Clecos
As an interesting aside, how many people have a wing in their dining room? This work was timed so that immediately afterwards I could remove the pilot wing (that fuel strake being complete) and install the other wing. The aileron and rudder work was then completed before beginning the co-pilot strake work.
Here, we're installing Fiberfrax and Stainless Steel onto the wing-roots as the factory-recommended fire protection for this area. As you can see, I've made a kraft paper template, then a rigid cardboard template, then cut the Fiberfrax, and still had to trim the stainless some after cutting the pattern out of it.
Paper Templates
Cardboard Template and Fiberfrax
Wing Root Fiberfrax in Place
Stainless Installed
Roll Push-Pull Cable Fire Sleeve
P - Chapter
2.3.9
- "Balancing Ailerons"
This section not yet complete.
Section 2.4 Vortilons & Vortex Generators
P - Chapter
2.4.1
- "Vortilons"
This section not yet complete, though I've purchased the VG's from CCI in New Jersey.
~ End of Chapter ~ End of Section ~