More aileron and autopilot servo work: 2 hours

I did the following: modified a stop bracket for the servo that limits movement in case of a failure, fabricated one more aileron spacer, and temporarily installed the aileron push pull tube and the bellcrank using the autopilot bracket to check the fit and movement.

It looks like I will have to make one more adjustment to get the clearance I need for the push pull tube.

 

My Garmin roll servo with the stop bracket installed.

 

Aileron bellcrank and push pull tube temporarily installed with Garmin mounting bracket.

 

Posted with Blogsy

Worked on right aileron install: 3.8 hours

I did the following: prepped and primed the various autopilot servo brackets and linkages, fabricated a spacer required for the aileron bracket, and installed the aileron with the various washers and spacers called out in the plans.

Fitting the aileron is a fairly slow process involving adding and removing washers to get the spacing right so the control push pull tubes can move through the full range with good clearance.

 

Posted with Blogsy

Finished flap, started mounting aileron: 5.8 hours

The final riveting on the flap went smoothly.

I then spent time organizing the parts for the aileron install and researching how the autopilot servo is mounted.

I have the aileron temporarily in place now.

 

Riveting the flap hinge:

 

All finished:

 

Posted with Blogsy

Right flap riveting: 6 hours

I made a lot of progress on the right flap today. All riveting is done with the exception of the hinge.

Unfortunately I put a small ding in the flap skin when the gun slipped while doing one of the difficult rivets. It's a cosmetic defect that will be easy to cover. I'm glad I'm going with paint instead of polished aluminum!

 

Getting started:

 

One of the difficult spots to reach:

 

Posted with Blogsy

Flap riveting: 2.2 hours

I got all the ribs riveted to the lower flap skin and clecoed the top skin on so I can start riveting that during the next session.

 

Lower skin in position to rivet:

 

Posted with Blogsy

Right flap priming and start of assembly: 4 hours

Finished the few dimples remaining on the skin then started cleaning and prepping all parts for priming.

After all the parts were primed I went over them with the heat gun to speed up the cure. Later in the evening I started riveting a few things.

 

The hand squeezer gives the best control for this kind of riveting:

 

Posted with Blogsy

Right flap parts prep: 3 hours

Finished all the deburring, scuffing and dimpling except for a few places on the flap top skin.

 

Flap top skin - almost ready:

 

 

Posted with Blogsy

Right flap countersink and more: 4 hours

Did the countersinking required on the bottom of the spar. This is a much slower process than dimpling but necessary to accommodate the hinge.

Also started deburring and edge finishing flap parts.

 

Countersinking using the hinge as a guide:

 

Posted with Blogsy