Entries for: Wings - Ailerons
| Entry Date: Sunday, Oct 30, 2005 (details) |
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| Rivet the Trailing Edge Joggles |
| Wings
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| Ailerons
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| 1.5 hours
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Riveted the trailing edge with the manufactured heads on the upper surface following typical riveting patterns.
*Note* We'll work on the counterweight arm slot at a later time.
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| Entry Date: Sunday, Oct 30, 2005 (details) |
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| Rivet the Forward Servo Tab Spar to the Aileron |
| Wings
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| Ailerons
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| 0.67 hours
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Installed the anti-servo tab on the aileron and checked for any twist.
Removed the anti-servo tab leaving the forward tab spar and half of the hinge cleco'd to the aileron.
Riveted the upper and lower spar lines with blind rivets.
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| Entry Date: Saturday, Oct 08, 2005 (details) |
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| Rivet the Servo Tab |
| Wings
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| Ailerons
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| 1 hours
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Assembled the lower servo tab skin to the spar.
Riveted the skin and the horn in place.
After checking alignment with the aileron drilled the trailing edge and riveted.
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| Entry Date: Saturday, Oct 08, 2005 (details) |
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| Drill the Trailing Edge Joggles |
| Wings
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| Ailerons
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| 0.6 hours
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Drilled the trailing edges joggles, removed cleco's, cleaned, and deburred.
Epoxyed the trailing edge skins, re-cleco'd, and left overnight to cure.
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| Entry Date: Saturday, Oct 08, 2005 (details) |
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| Rivet the Skin to the Lower Flanges of the Aft Ribs |
| Wings
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| Ailerons
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| 1.5 hours
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Blind-riveted all flanges of the aft ribs except for the two outside ribs.
Riveted the end ribs using hard rivets.
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| Entry Date: Saturday, Oct 08, 2005 (details) |
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| Rivet the Inspection Hole Doublers to the Skin |
| Wings
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| Ailerons
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| 1.25 hours
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Riveted the doublers to the skin using access through the inspection holes.
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| Entry Date: Saturday, Oct 08, 2005 (details) |
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| Rivet the Skin and the Aft Insp. Cover Nutplates to the Lower Spar Flange |
| Wings
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| Ailerons
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| 3.25 hours
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Riveted the skin to the lower flanges of the spar, accessed by lifting the skin.
Flush riveted the aft nutplates for the inspection hole covers.
Riveted any locations that conflicted with ribs using blind rivets.
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| Entry Date: Thursday, Oct 06, 2005 (details) |
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| Rivet the Skin to the Lower Flanges of the Nose Ribs |
| Wings
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| Ailerons
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| 1.25 hours
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Riveted the skin to the lower flanges of the nose ribs using blind rivets except for the ends and the ribs accessible through the inspection holes.
Riveted all remaining nose ribs with hard rivets.
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| Entry Date: Saturday, Oct 01, 2005 (details) |
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| Rivet the Inspection Hole Doublers to the Spar |
| Wings
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| Ailerons
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| 0.75 hours
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Riveted the doublers to the spar.
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| Entry Date: Saturday, Oct 01, 2005 (details) |
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| Rivet the Skin to the Upper Flanges of the Spar, Aft Ribs, and Nose Ribs |
| Wings
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| Ailerons
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| 5.67 hours
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Riveted the skin to the upper flanges of the spar and aft ribs (following regular riveting patterns).
Realigned any crooked nose ribs and hard-riveted all but the last and any ribs accessible through inspection holes or ends.
*Note: If you're curious, the white plastic skin is the Right aileron and the clear plastic is the Left.*
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| Entry Date: Saturday, Oct 01, 2005 (details) |
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| Rivet Ribs to the Spar |
| Wings
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| Ailerons
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| 4 hours
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*NOTE* We didn't follow the order for riveting in the manual. It didn't make much sense and we saw no harm in changing the order.
Riveted the aft and nose ribs to the spar.
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| Entry Date: Friday, Sep 30, 2005 (details) |
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| Rivet Rib Pairs to Their Hinge Brackets and to the Spar |
| Wings
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| Ailerons
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| 2.4 hours
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Riveted both rib pairs to their respective hinge brackets.
Riveted the hinge brackets to the spar.
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| Entry Date: Wednesday, Sep 28, 2005 (details) |
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| Rivet Nutplates in Nose Ribs and Inspection Hole Doublers |
| Wings
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| Ailerons
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| 2.25 hours
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Riveted the hinge and actuator bolt nutplates to nose rib pairs B and C.
Riveted the counterweight bolt nutplates to the counterweight nose ribs.
Riveted the inspection hole cover nutplates to the doublers.
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| Entry Date: Sunday, Sep 25, 2005 (details) |
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| Corrosion-Proof the Aileron Interiors |
| Wings
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| Ailerons
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| 8 hours
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Cleaned and prepared aft/nose ribs, doublers, and smaller 'spars' in the anti-servo tab with Alumaprep and Alodine.
Cleaned spars, servo tab skins, and skins with PreKote.
Painted all pieces using zinc-chromate primer.
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| Entry Date: Thursday, Sep 15, 2005 (details) |
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| Clean and Deburr all Aileron Parts |
| Wings
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| Ailerons
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| 3 hours
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Disassembled both ailerons and the servo tab. Deburred all holes and removed any chips on the parts.
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| Entry Date: Thursday, Sep 15, 2005 (details) |
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| Install the Servo Tab on the Aileron |
| Wings
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| Ailerons
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| 3.5 hours
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Positioned the forward edge of the hinge between the upper skin and the spar. Trimmed skin from the aileron to ensure correct gap spacing.
Clamped in place and checked tab deflection (18 degree's up, 23 down).
Marked rivet positions along the upper hinge line and lower spar line, drilled.
Centered the servo horn in place and drilled the four #40 holes, making sure the horn was perpendicular.
Disassembled and deburred.
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| Entry Date: Saturday, Sep 10, 2005 (details) |
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| Drill and Assemble the Servo Tab |
| Wings
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| Ailerons
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| 4 hours
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Trimmed the bottom servo tab skin to 2.34", cleaned and deburred.
Positioned the aft spar so the lower corner matched the lower skin edge. Taped the parts together.
Positioned the upper servo tab skin over this assembly and inserted the hinge.
Marked the rivet pattern along the skins.
Drilled the upper hinge line with a #30 and cleco'd. Drilled the lower trailing edge with #40's.
Disassembled, deburred, and rejoined all parts.
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| Entry Date: Sunday, Sep 04, 2005 (details) |
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| Trim the Ribs and Install the Forward Spar |
| Wings
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| Ailerons
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| 1 hours
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Removed the two inboard ribs. Trimmed outboard one to 6.5", making sure to keep edge margins correct for the last rivet along the rib.
Marked the inboard rib against the skins and trimmed.
Re-installed the ribs and installed the forward servo spar.
Attached the spar using double-sided tape.
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| Entry Date: Sunday, Sep 04, 2005 (details) |
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| Layout and Mark the Servo Tab on the Left Skin |
| Wings
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| Ailerons
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| 1 hours
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Marked a line along the inboard surface of the upper skin. Marked the same line on the surface of the lower skin.
Using snips and Dremel, trimmed along these lines until the material was removed.
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| Entry Date: Wednesday, Jul 27, 2005 (details) |
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| Positon and Drill the Inspection Hole Cover Nutplates |
| Wings
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| Ailerons
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| 1.17 hours
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Drilled the locations for the three nutplates that will secure the inspection hole cover.
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| Entry Date: Saturday, Jul 23, 2005 (details) |
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| Position and Drill the Upper Surface of the Skin |
| Wings
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| Ailerons
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| 3.5 hours
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Rotated the assembly over and gradually clamped the top skin down.
Made sure everything was as straight/flat as possible, tested for twist, and drilled the skin.
Spar -> aft along the ribs -> forward along the nose ribs.
Upsized any holes requiring #30.
*The right skin didn't fit as nicely as the left and took us quite a bit longer to get into place.*
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| Entry Date: Saturday, Jul 23, 2005 (details) |
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| Mark and Drill the Spar Web/Inspection Hole Doubler Rivet Holes |
| Wings
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| Ailerons
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| 1 hours
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Put the cover plates in place and drilled the four pilot holes for the mounting screws.
Deburred the holes.
Flipped the aileron assembly and marked the hole locations on the tabs of each doubler.
Drilled and deburred.
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| Entry Date: Saturday, Jul 23, 2005 (details) |
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| Mark, Position, and Drill the Inspection Hole Doublers |
| Wings
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| Ailerons
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| 2.5 hours
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Marked the eleven holes needed to rivet the doubler to the skin while maintaining proper edge margins.
Clamped the doublers in place and drilled/cleco'd all marked holes.
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| Entry Date: Friday, Jul 22, 2005 (details) |
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| Position and Drill the Lower Surface Rivet Holes |
| Wings
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| Ailerons
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| 4 hours
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Aligned the left skin on the assembly and clamped in place with cleco-clamps along the ends. Followed standard procedures to drill out all rivet holes.
Made sure to keep checking the alignment of the pilot holes with the rivet lines marked on the ribs/spar.
**NOTE: We had to spend extra time on each aileron reshaping the flanges on ribs. Neither side had a nice flat transition from rib-spar-nose rib. Leaving these alone would've created dimples and waves in our skin.**
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| Entry Date: Friday, Jul 22, 2005 (details) |
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| Clamp the Spar/Rib Assembly to the Table |
| Wings
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| Ailerons
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| 0.6 hours
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Mounted two pieces of aluminum angle to the edge of our building table.
Cleco-clamped the assembly (upside down with the nose ribs hanging out) to these pieces. Used a 6' long piece of 1/4" thick wood to support the aft ribs.
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| Entry Date: Thursday, Jul 21, 2005 (details) |
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| Cleco the Remaining Ribs to the Spar and Drill All Holes to Final Size |
| Wings
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| Ailerons
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| 1 hours
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Cleco'd all the ribs (nose, aft, and counterweight) to the spar.
Fit a spacer between the counterweight nose ribs to hole them apart correctly for drilling.
Drilled all spar/rib rivet holes up to final size.
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| Entry Date: Friday, Jul 15, 2005 (details) |
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| Mark and Drill the Hinge Brackets |
| Wings
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| Ailerons
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| 1.34 hours
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Cleco'd the nose rib pairs to the spar and checked spacing for the hinge brackets.
Removed the brackets, measured out the rivet hole spacing, center-punched, and drilled the pilot holes.
Aligned each bracket using the hinge/actuator bolts and drilled up the six rivet holes to final size.
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| Entry Date: Thursday, Jul 14, 2005 (details) |
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| Dimple the Ribs and Nutplates |
| Wings
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| Ailerons
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| 0.84 hours
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(Have not dimpled the nutplates yet.)
Dimpled the ribs to accommodate flush rivets. Made sure to dimple the correct side of the ribs as the back of the nutplate will be inaccesible once everything is riveted together.
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| Entry Date: Thursday, Jul 14, 2005 (details) |
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| Drill All Bolt/Nutplate Holes in Ribs Pairs B & C |
| Wings
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| Ailerons
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| 1.25 hours
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Drilled the hinge and actuator bolt holes.
Marked and drilled the counterweight bolt holes.
Positioned and drilled the bolt nutplates.
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| Entry Date: Thursday, Jul 14, 2005 (details) |
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| Straighten and Deburr the Parts / Mark Rivet Lines |
| Wings
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| Ailerons
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| 2 hours
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*NOTE: We will be adding the times for Left/Right sides together but leaving the dates set at when we completed the Left side. And since the sides are pretty much mirror images we'll only add seperate pictures if the part differs enough.*
Used a square to check the flanges on all of the ribs (Left and Right). Deburred and straightened.
Marked rivet lines along ribs/spar using our line tool.
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