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August 2, 2005:
(2.5hrs.) With the majority of both wings done (still need
to attach the bottom skin), I decided to move on to the ailerons.
These go together much like the rudder.
There is a whole slew of stiffeners that need to be cut from these aluminum angles.
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After using my Wiss cutters to separate
all the stiffeners, the next step is to mark and then cut the angles.
Van's is nice enough to place little punch marks where you need to make
the cuts.
Here I have marked a stiffener (from the center of punch mark to punch mark) for cutting. |
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All 36 stiffeners cut. That was a chore. |
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Next, the arduous task of smoothing and
deburring the edges of each stiffener.
First, I used my 6" bench top sanding disc to straighten all the cut edges. You have to be careful here to not remove too much material. |
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Sanding is followed by grinding with the
Scotchbrite wheel on the bench top grinder. All the corners are
radiused and edges smoothed.
After completing this process on all 36 stiffeners, I decided to call it a day. |
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August 3, 2005:
(3.0 hrs.) Cleco'd the stiffeners to the top and bottom of
both aileron skins and then matched drilled them with a #40 bit.
I then proceeded to debur and dimple each hole in the stiffeners. |
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The stiffeners were cleaned with Alumiprep
and then Alodined. Here the are hanging outdoors to dry.
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Stiffeners are painted. |