Hi Netters, I enjoyed the photographs on Jerry & Dan's Aircraft Factory covering the aileron construction. May I suggest that instead of melting lead and pouring it into a mold, you consider making a Styrofoam plug, the size of the weight. put a layer of fiberglass on it. After it is hard, pour gasoline onto the Styrofoam to remove it. Now instead of hot lead just pour in lead shot mixed with automobile wheel weight, scrap lead pieces etc. (something like making concrete,(leadcrete LOL). Now if the correct weight had been used , pour onto the lead a fluid epoxy mix. It will fill the voids and lock the pieces of epoxy in place. You could have imbedded the aluminum arm in to the mix but put some holes and a bolt in it to act as an anchor in the leadcrete.Finish the outside of the balance weight ready for painting. Do a trial balance. If it is too heavy, drill out some of the lead and cover the hole with a foam plug and micro. I would be remiss if I did not issue the warning about the lead. Lead dust from sanding is very dangerous from a health point of view. It is after the small particles oxidize that the fun begins. If you inhale this oxide or get it into your body by any means you will inherit the nasty toxic effect of lead poisoning. Wear a mask , vacuum up all of the lead dust around the workshop, wash your hands. After all, you do want to pass your medical in the future, to fly your creation. Good luck Regards, Harold Woods Orillia,ON.Canada.
haroldwo...@rogers.com
