Ailerons


Ailerons 15 (1.5 hrs)

Tonight I reamed the bell crank bushings. I ordered a 0.2490 reaming bit off of Amazon. The bolts are slightly undersized. There is no need to go the full 0.25 inches. Further if you ream with a regular bit you could scar the inside of the bushing. Remember the bell crank rotates about the bushing. The bushing does not rotate around the bolt. Since this will connect to the control stick, I’d like to keep tolerances as tight as possible so that the controls have minimal slop over the life of the aircraft.

To ream the bushing, I drilled a hole in a 2/4 with the drill press the same size as the bushing outer diameter. I then put the bushing in the hole, and reamed the center, using the 2×4 as a jig.

Next I drilled the short aileron push rods. Be careful these can be a bit tricky. 


Ailerons 14 (1.0 hr)

Now that the flaps and ailerons are complete its time for connecting the bell crank and pushrods. This should be a relatively quick project. Unfortunately, today’s weather cut my shop time short.

I started out by measuring the two push rods. Be careful, there are separate measurements for the RV-7 and the RV-8. (null)

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I wrapped a yellow post it note around each pushrod to get a perfectly circular measurement. As always, I marked the bad side with “X”s so that I know which side of the line to cut. I will clean up with a file before priming. Speaking of priming, I haven’t quite decided on which primer I will use. I sometimes use the basic self-etching primer in a can for small parts, but these parts are important enough that I may break out the AKZO. We’ll see which I pick.

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Before I cut the rods, I wanted to make sure I understood how everything connected. I also needed to do some organizing. Turns out there are several types of bolts that I have never separated into different bins. I took care of that quickly. I also cleaned out some of the holes on the powder coated bell crank. Van’s does not do a good job of deburring these parts prior to powder coating. Steel isn’t nearly as susceptible to stress cracks as aluminum, but still its slightly annoying. I debated cleaning it up further, which would require additional primer. In the end I decided if its good enough for Van’s, its good enough for me. (null)

Then I cut the push rods to size. (null)

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There is a lot more snow than it looks like in this picture. The wind is pushing it into drifts. By this time we had close to a foot, and it was still coming down. I figured I shouldn’t push my luck and decided to head home. (null)

Squire quite enjoyed himself!(null)

Four wheel drive or not, with the windshield wipers struggling, I’m glad I went home before dark. It gave me the opportunity to shovel. YAY!(null)


Ailerons 13 (2.0 hrs)

I continued where I left off on the top spar.  This is a pain in the butt. Here you can see my flashlight illuminating the rivets already completed. IMG_5899.JPG

After I finished the top of the spar, it was time to rivet the tops of the nose ribs. And the main ribs. IMG_5900.JPG

Then it was time to move on to the bottom. I dip each pop rivet in primer prior to riveting the counterweight pipe.  Additionally, I fixed Mike’s pneumatic pop rivet tool.  It works pretty well, but boy does it leak oil.IMG_5901.JPG

A few pictures of the final product.  Ailerons are complete!  There isn’t a lot left to do on the wings!IMG_5902.JPG

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