Someone is ready to cut out the ailerons. Let me tell you how this
story ends if you do it the way I did it.
I laid out all the dimensions for the cut and attached a long straight
edge on the cut line. Using a small Dremel I made the most beautiful
straight cuts you can imagine by biasing the cutter along the straight
edge. I moved the aileron to the workbench to finish. I removed some
foam and installed the spruce spar with hinge attached and blind nuts
epoxied to the back side of the spar to accept the hinge attach screws.
I laid up several layers of "deck cloth" over the edges and around the
spar as it lays down so nicely over corner edges. I let it cure and
re-attached it to the wing with the hinge pin.
Months later:
I attached the wing to the KR and what's this? The aileron matches the
wing at the tip but not the stub wing. When it matches at the stub wing
it doesn't line up at the tip. WHAT THE H****? DUH....... the wing has
a 3 degree washout and I built the aileron on a flat work bench. O.K.,
now what. With the wing attached I clamped the aileron to the wing at
the outboard end. I used the small Dremel cutoff wheel and cut the
glass on the top side of the aileron at the back edge of the aileron
spar for about 80 percent the length of the aileron. That allowed the
aileron to flex (twist) and I then clamped the aileron to match at the
stub wing. The void was filled with flox and allowed to cure. After
curing I removed the aileron from the wing and laid several more layers
of "deck cloth" over the cut and over the corner to the spar. If you
look at the photo of the KR I posted earlier you will see how nicely it
turned out. Given my screw up I'm really not sure how to do it
correctly. Possibly gluing only the bottom edge of the spar to the
aileron, mount on the KR, clamp both ends, and then glue the top edge.
Let cure, remove and finish.
Larry Flesner
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