{"id":938,"date":"2020-08-24T17:00:00","date_gmt":"2020-08-25T00:00:00","guid":{"rendered":"https:\/\/sling2.slantalpha.com\/wp\/?p=938"},"modified":"2020-11-02T11:34:27","modified_gmt":"2020-11-02T19:34:27","slug":"ailerons-fab-rework-and-pre-assembly","status":"publish","type":"post","link":"https:\/\/sling2.slantalpha.com\/wp\/?p=938","title":{"rendered":"Ailerons &#8211; Fab, Rework and Pre-Assembly"},"content":{"rendered":"\n<p>Aileron assembly has been delayed by ignorance and procrastination. It&#8217;s amazing how long it took me to decide to lever $20 out of my pocket for a tool. There&#8217;s an anchor nut that gets attached to a rib with a couple of stainless steel rivets that have a 120 degree countersink. I was reluctant to spring for a 120 degree, #40 pilot cutter. This left me pondering various alternative ways I might proceed to attach the anchor nuts. The door was left open because the construction manual doesn&#8217;t say anything about it. But, I did have reference examples &#8211; other builder&#8217;s and identical anchor nuts mounted in my quick-build fuselage. I finally ended up getting the stupid pilot cutter and  then mounted the anchor nuts as I knew they should be from the very beginning.<\/p>\n\n\n\n<style id=\"bwg-style-0\">    #bwg_container1_0 #bwg_container2_0 .bwg-container-0.bwg-standard-thumbnails {      width: 1254px;              justify-content: center;        margin:0 auto !important;              background-color: rgba(255, 255, 255, 0.00);            padding-left: 4px;      padding-top: 4px;      max-width: 100%;            }        #bwg_container1_0 #bwg_container2_0 .bwg-container-0.bwg-standard-thumbnails .bwg-item {    justify-content: flex-start;      max-width: 250px;          }    #bwg_container1_0 #bwg_container2_0 .bwg-container-0.bwg-standard-thumbnails .bwg-item a {       margin-right: 4px;       margin-bottom: 4px;    }    #bwg_container1_0 #bwg_container2_0 .bwg-container-0.bwg-standard-thumbnails .bwg-item0 {      padding: 0px;            background-color:rgba(0,0,0, 0.30);      border: 0px none #CCCCCC;      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#323A45;      font-family: Ubuntu;      font-size: 16px;      font-weight: bold;      padding: 2px;      text-shadow: ;      max-height: 100%;    }    #bwg_container1_0 #bwg_container2_0 .bwg-container-0.bwg-standard-thumbnails .bwg-thumb-description span {    color: #323A45;    font-family: Ubuntu;    font-size: 12px;    max-height: 100%;    word-wrap: break-word;    }    #bwg_container1_0 #bwg_container2_0 .bwg-container-0.bwg-standard-thumbnails .bwg-play-icon2 {      font-size: 32px;    }    #bwg_container1_0 #bwg_container2_0 .bwg-container-0.bwg-standard-thumbnails .bwg-ecommerce2 {      font-size: 19.2px;      color: #323A45;    }    <\/style>    <div id=\"bwg_container1_0\"         class=\"bwg_container bwg_thumbnail bwg_thumbnails \"         data-right-click-protection=\"0\"         data-bwg=\"0\"         data-scroll=\"0\"         data-gallery-type=\"thumbnails\"         data-gallery-view-type=\"thumbnails\"         data-current-url=\"\/wp\/index.php?rest_route=%2Fwp%2Fv2%2Fposts%2F938\"         data-lightbox-url=\"https:\/\/sling2.slantalpha.com\/wp\/wp-admin\/admin-ajax.php?action=GalleryBox&#038;current_view=0&#038;gallery_id=37&#038;tag=0&#038;theme_id=1&#038;shortcode_id=79&#038;sort_by=filename&#038;order_by=asc&#038;current_url=%2Fwp%2Findex.php%3Frest_route%3D%252Fwp%252Fv2%252Fposts%252F938\"         data-gallery-id=\"37\"         data-popup-width=\"800\"         data-popup-height=\"500\"         data-is-album=\"gallery\"         data-buttons-position=\"bottom\">      <div id=\"bwg_container2_0\">             <div id=\"ajax_loading_0\" class=\"bwg_loading_div_1\">      <div class=\"bwg_loading_div_2\">        <div class=\"bwg_loading_div_3\">          <div id=\"loading_div_0\" class=\"bwg_spider_ajax_loading\">          <\/div>        <\/div>      <\/div>    <\/div>            <form id=\"gal_front_form_0\"              class=\"bwg-hidden\"              method=\"post\"              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with Film\"                   title=\"Aileron Skin with Film\" \/>            <\/div>            <div class=\"\">                                                      <\/div>          <\/div>        <\/div>                <div class=\"bwg-title1\"><div class=\"bwg-title2\">Aileron Skin with Film<\/div><\/div>        <\/a>              <\/div>            <div class=\"bwg-item\">        <a class=\"bwg-a  bwg_lightbox\"  data-image-id=\"350\" href=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/IMG_1447.jpeg?bwg=1604170556\" data-elementor-open-lightbox=\"no\">                <div class=\"bwg-item0  lazy_loader \">          <div class=\"bwg-item1 \">            <div class=\"bwg-item2\">              <img decoding=\"async\" class=\"skip-lazy bwg_standart_thumb_img_0  bwg_lazyload \"                   data-id=\"350\"                   data-width=\"500\"                   data-height=\"375\"                   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Pull Beautifully<\/div><\/div>        <\/a>              <\/div>            <div class=\"bwg-item\">        <a class=\"bwg-a  bwg_lightbox\"  data-image-id=\"348\" href=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/IMG_1449.jpeg?bwg=1604170556\" data-elementor-open-lightbox=\"no\">                <div class=\"bwg-item0  lazy_loader \">          <div class=\"bwg-item1 \">            <div class=\"bwg-item2\">              <img decoding=\"async\" class=\"skip-lazy bwg_standart_thumb_img_0  bwg_lazyload \"                   data-id=\"348\"                   data-width=\"375\"                   data-height=\"500\"                   data-src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/thumb\/IMG_1449.jpeg?bwg=1604170556\"                   src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/plugins\/photo-gallery\/images\/lazy_placeholder.gif\"                   alt=\"\"     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class=\"bwg-item2\">              <img decoding=\"async\" class=\"skip-lazy bwg_standart_thumb_img_0  bwg_lazyload \"                   data-id=\"346\"                   data-width=\"375\"                   data-height=\"500\"                   data-src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/thumb\/IMG_1451.jpeg?bwg=1604170556\"                   src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/plugins\/photo-gallery\/images\/lazy_placeholder.gif\"                   alt=\"Needed 120 degree #40 pilot cutter for stainless steel anchor nut rivets\"                   title=\"Needed 120 degree #40 pilot cutter for stainless steel anchor nut rivets\" \/>            <\/div>            <div class=\"\">                                                      <\/div>          <\/div>        <\/div>                <div class=\"bwg-title1\"><div class=\"bwg-title2\">Needed 120 degree #40 pilot cutter for stainless steel anchor nut rivets<\/div><\/div>        <\/a>              <\/div>            <div class=\"bwg-item\">        <a class=\"bwg-a  bwg_lightbox\"  data-image-id=\"345\" href=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/IMG_1452.jpeg?bwg=1604170556\" data-elementor-open-lightbox=\"no\">                <div class=\"bwg-item0  lazy_loader \">          <div class=\"bwg-item1 \">            <div class=\"bwg-item2\">              <img decoding=\"async\" class=\"skip-lazy bwg_standart_thumb_img_0  bwg_lazyload \"                   data-id=\"345\"                   data-width=\"375\"                   data-height=\"500\"                   data-src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/thumb\/IMG_1452.jpeg?bwg=1604170556\"                   src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/plugins\/photo-gallery\/images\/lazy_placeholder.gif\"                   alt=\"Practice Countersink Technique and Micro-Stop Setup\"                   title=\"Practice Countersink Technique and Micro-Stop Setup\" \/>            <\/div>            <div class=\"\">                                                      <\/div>          <\/div>        <\/div>                <div class=\"bwg-title1\"><div class=\"bwg-title2\">Practice Countersink Technique and Micro-Stop Setup<\/div><\/div>        <\/a>              <\/div>            <div class=\"bwg-item\">        <a class=\"bwg-a  bwg_lightbox\"  data-image-id=\"344\" href=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/IMG_1453.jpeg?bwg=1604170556\" data-elementor-open-lightbox=\"no\">                <div class=\"bwg-item0  lazy_loader \">          <div class=\"bwg-item1 \">            <div class=\"bwg-item2\">              <img decoding=\"async\" class=\"skip-lazy bwg_standart_thumb_img_0  bwg_lazyload \"                   data-id=\"344\"                   data-width=\"375\"                   data-height=\"500\"                   data-src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/thumb\/IMG_1453.jpeg?bwg=1604170556\"                   src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/plugins\/photo-gallery\/images\/lazy_placeholder.gif\"                   alt=\"Countersinking Ribs \"                   title=\"Countersinking Ribs \" \/>            <\/div>            <div class=\"\">                                                      <\/div>          <\/div>        <\/div>                <div class=\"bwg-title1\"><div class=\"bwg-title2\">Countersinking Ribs <\/div><\/div>        <\/a>              <\/div>            <div class=\"bwg-item\">        <a class=\"bwg-a  bwg_lightbox\"  data-image-id=\"343\" href=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/IMG_1454.jpeg?bwg=1604170556\" 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class=\"bwg-title2\">Countersunk Rivet - Test Fit<\/div><\/div>        <\/a>              <\/div>            <div class=\"bwg-item\">        <a class=\"bwg-a  bwg_lightbox\"  data-image-id=\"342\" href=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/IMG_1455.jpeg?bwg=1604170556\" data-elementor-open-lightbox=\"no\">                <div class=\"bwg-item0  lazy_loader \">          <div class=\"bwg-item1 \">            <div class=\"bwg-item2\">              <img decoding=\"async\" class=\"skip-lazy bwg_standart_thumb_img_0  bwg_lazyload \"                   data-id=\"342\"                   data-width=\"375\"                   data-height=\"500\"                   data-src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/thumb\/IMG_1455.jpeg?bwg=1604170556\"                   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class=\"bwg-item0  lazy_loader \">          <div class=\"bwg-item1 \">            <div class=\"bwg-item2\">              <img decoding=\"async\" class=\"skip-lazy bwg_standart_thumb_img_0  bwg_lazyload \"                   data-id=\"353\"                   data-width=\"500\"                   data-height=\"375\"                   data-src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/thumb\/IMG_1671.jpeg?bwg=1604334973\"                   src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/plugins\/photo-gallery\/images\/lazy_placeholder.gif\"                   alt=\"Aileron Hinge Bolt Not Aligned\"                   title=\"Aileron Hinge Bolt Not Aligned\" \/>            <\/div>            <div class=\"\">                                                      <\/div>          <\/div>        <\/div>                <div class=\"bwg-title1\"><div class=\"bwg-title2\">Aileron Hinge Bolt Not Aligned<\/div><\/div>        <\/a>              <\/div>            <div class=\"bwg-item\">        <a class=\"bwg-a  bwg_lightbox\"  data-image-id=\"352\" href=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/IMG_1672.jpeg?bwg=1604334971\" data-elementor-open-lightbox=\"no\">                <div class=\"bwg-item0  lazy_loader \">          <div class=\"bwg-item1 \">            <div class=\"bwg-item2\">              <img decoding=\"async\" class=\"skip-lazy bwg_standart_thumb_img_0  bwg_lazyload \"                   data-id=\"352\"                   data-width=\"500\"                   data-height=\"375\"                   data-src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/thumb\/IMG_1672.jpeg?bwg=1604334971\"                   src=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/plugins\/photo-gallery\/images\/lazy_placeholder.gif\"                   alt=\"Prepare to Drill Out Rivets\"                   title=\"Prepare to Drill Out Rivets\" \/>            <\/div>            <div class=\"\">                                                      <\/div>          <\/div>        <\/div>                <div class=\"bwg-title1\"><div class=\"bwg-title2\">Prepare to Drill Out Rivets<\/div><\/div>        <\/a>              <\/div>            <div class=\"bwg-item\">        <a class=\"bwg-a  bwg_lightbox\"  data-image-id=\"351\" href=\"https:\/\/sling2.slantalpha.com\/wp\/wp-content\/uploads\/photo-gallery\/imported_from_media_libray\/IMG_1673.jpeg?bwg=1604334971\" data-elementor-open-lightbox=\"no\">                <div class=\"bwg-item0  lazy_loader \">          <div class=\"bwg-item1 \">            <div class=\"bwg-item2\">              <img decoding=\"async\" class=\"skip-lazy bwg_standart_thumb_img_0  bwg_lazyload \"                   data-id=\"351\"                   data-width=\"375\"                   data-height=\"500\"                   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<\/style>        <div id=\"bwg_spider_popup_loading_0\" class=\"bwg_spider_popup_loading\"><\/div>        <div id=\"spider_popup_overlay_0\" class=\"spider_popup_overlay\" onclick=\"spider_destroypopup(1000)\"><\/div>        <input type=\"hidden\" id=\"bwg_random_seed_0\" value=\"1439650751\">                <\/div>    <\/div>    <script>      if (document.readyState === 'complete') {        if( typeof bwg_main_ready == 'function' ) {          if ( jQuery(\"#bwg_container1_0\").height() ) {            bwg_main_ready(jQuery(\"#bwg_container1_0\"));          }        }      } else {        document.addEventListener('DOMContentLoaded', function() {          if( typeof bwg_main_ready == 'function' ) {            if ( jQuery(\"#bwg_container1_0\").height() ) {             bwg_main_ready(jQuery(\"#bwg_container1_0\"));            }          }        });      }    <\/script>    \n\n\n\n<p>Another self-inflicted setback has been in play. Sometime earlier, I&#8217;d riveted one of the aileron hinge bracket and rib sub-assemblies together. Unfortunately, something I&#8217;d noticed, but dismissed during initial fitting, had to be corrected. The bolt holes on the inner and outer aileron hinge brackets were not in alignment. To compound the problem, I reasoned that it would probably be ok to ream the bolt holes a little &#8211; make them oblong &#8211; and somehow that work out ok. Wrong! The result was better alignment, but at the cost of precision (proper) fit.<\/p>\n\n\n\n<p>Sloppy fit for the outer aileron hinge just isn&#8217;t going to cut it. What could I do? Eventually, I did what I I should have done in the first place &#8211; ask the factory for guidance. I sent an email and got an overnight response directly from <em>Mike Blyth<\/em> &#8211; designer of all <em>Sling Aircraft<\/em> models. The outer bracket just needs to be bent a bit more. So simple! That absolutely did not occur to me. Sadly, I&#8217;d ruined (by reaming) the inner and outer brackets for one aileron and needed new ones. TAF USA rushed me replacements. Fantastic service!<\/p>\n\n\n\n<p>With new brackets in hand, I slightly increased the bends on the outer brackets for both ailerons, removed the old brackets from one of the ribs and riveted all of the sub-assemblies together. Beautiful! I can sleep again. No more worries thinking about how I would try to rationalize wobbly ailerons to myself, the DAR, my technical counselors and everyone else.<\/p>\n\n\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Aileron assembly has been delayed by ignorance and procrastination. It&#8217;s amazing how long it took me to decide to lever $20 out of my pocket for a tool. There&#8217;s an anchor nut that gets attached to a rib with a couple of stainless steel rivets that have a 120 degree countersink. I was reluctant to [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[90,76],"tags":[57,92,65,56,91,39],"acf":[],"_links":{"self":[{"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=\/wp\/v2\/posts\/938"}],"collection":[{"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=938"}],"version-history":[{"count":14,"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=\/wp\/v2\/posts\/938\/revisions"}],"predecessor-version":[{"id":972,"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=\/wp\/v2\/posts\/938\/revisions\/972"}],"wp:attachment":[{"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=938"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=938"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/sling2.slantalpha.com\/wp\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=938"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}