Aileron Installation

This blog covers the final installation details for the ailerons.

Overview
The ailerons had been assembled previously leaving the final details to the final installation.

Installation

Note two [2] washers

With these issues sorted and a lot of lost time, the only practical way to assemble the brackets then connect the aileron was to fit the brackets to the aircraft first.

Both bearing mount require an AN4 aluminium washer to be inserted on both sides between the face of the bracket to avoid fouling but on final installation the inboard mount required two [2] on one side to clear the rivets. 

The next task was to fit the rod end bearing, to locate the bearing, a pair of 3 mm spacers were machined from 4130 tube to fix the rod end location. Additionally two [2] seal were added to protect the working face from the environment.

Stainless steel and aluminium have some known corrosion issues so all mounting face were painted in SLS Etch primer before installation. 

Primer on mounting faces

With both hinges fitted the aerlion was mounted with AN3 bolts / washers using the captive nut fitted to the spar. This task is not easy and dose require the use of a set of fine bent long nose pliers, assorted tools and floor gymnastics on the trolley.

Leveling Aileron

The next task was to adjust the shaft connection between the aileron / bell crank located in the wing. This required locking the aileron into a their neutral position, this was achieved  using a piece of aluminium angle and clamps.

Next the push pull tube was placed in it neutral using the center rocker arm, this was placed perpendicular to the spar face. The rod end at the bell crank was unbolted and adjusted in conjunction with the one attached to the aileron bracket, when correct the lock nuts were tightened and wax marked.

Note: It is critical this be undertaken while access is available from the underside of the wing  as there is no access to the rod end bearing on the bellcrank with the skin on.

Bell Crank

A particular issue that appeared was that the end rib was not square and this required a small amount of Plasti-Bond to be applied and sanded to achieve a flat face, once sanded the mass balance was reinstalled using three [3] M5 x 16 mm Titanium Button head screws.

Note: Screws were used over rivets at installation as it was suspected that something was not 100%.

This was noted when the tip was installed and will be covered in that blog at a later date.

Mass Balance and filler [upper right hand corner}

Comment
Generally straightforward once the best way to achieve assembly was understood.