Tag: Ailerons

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A couple days’ work

Saturday: Ripped the CW37 parts down to the proper 1/4″ thickness. These are the strips with one beveled edge that go in the top and bottom of the aileron bay. The parts I got are 1/2″ thick, which won’t work anywhere. Ripped them all down to 1/4″ so I don’t have to do that again for the other two wings. With them cut to the right thickness, I cut one to length and glued it into the bottom of the aileron bay.

Then I discovered (or confirmed) that I’m an idiot… there were a couple of missing aileron pieces that I found in the bottom of the parts crate. Had I installed them in the first place, the little triangular braces would not have been needed. It’s no big deal; I was able to slot the nose skin support spar and get them glued in.

Today: Got the nose skin plywood glued onto the front of the wing. I think there are now about 70 or more clamps on the wing. I had planned to glue the top aileron nose skin in place, but that’s going to take some more work. I see no way to get that ply to stay attached all the way around without some sort of clamping jig. Stu and I figured out a good arrangement, but I’ll need to get some MDF, ply, or pine scrap to cut them out of. I need seven sets of clamping blocks for the nose and trailing edge, then I can use bar clamps to hold everything in place.

I also found that a few batches of glue I mixed up over the past week or two were probably not the greatest. My T88 had started getting cloudy — a sign that the resin is starting to crystallize. Some of my test pieces failed at the glue joint, albeit with a lot of force required, instead of the wood failing before the joint. I’m not really concerned about this. All of the affected glue was used for either the wing walk or adding corner blocking and gussets to the wingtip bow. The wing walk pieces are fully supported and there will be no bending, twisting, or pulling loads applied. The glue is strong, just not AS strong as what I’ve used everywhere else.

I have since tossed the syringe of clouded resin, warmed the rest of my resin supply until it’s crystal clear, and verified that test pieces now all break well into the wood rather than at the glue line. I’ve tried spruce to spruce, which tore apart well into the wood, and spruce to plywood which ripped the plywood apart.

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Bracing and gusseting

I got all the clamps off of the aileron this afternoon. Everything looks pretty good. Due to the way I had to cut the thin nose skin spar, I felt it best to install some bracing for it. These are just little half inch right triangles that I glued in to keep it straight.

With that done, I removed the clamps from the wingtip bow and sanded down the gussets I’d installed last time. I won’t know if they require any “fine tuning” until I have a chance to get some fabric on it, but I think they’re good to go.

I flipped the wing on its top surface and added some more blocking under the ends of the wing walk. These are just regular corner block stock to tie the plywood to the spar caps. I think everything looks pretty sturdy there now.

With some time and glue left, I sanded down the corner blocks on the underside of the wingtip bow supports. I cut, glued, and clamped the gussets in place and called it a day.

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On a roll!

Today I did some work with the razor plane and a new sanding block to get the aileron spar and other bits to their final dimensions. I got the top side geodetic braces cut and glued in place on the aileron. Then I glued the lower aileron nose skin in place – the aileron now has, I think, the maximum possible number of clamps on it.

With that done, I got the blocking sanded down on the wingtip bow supports, and cut and glued the top gussets in place. Only eight clamps there, but I think it’s still feeling the love.

And if you’re a Star Trek: Voyager fan, this makes Seven of Nine days in September that I’ve worked on the plane.

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Aileron work

I removed the clamps from the wing walk skins; all looks good. Once I have the wing flipped upside-down again I’ll have a look at the underside and see if there are any additional opportunities to put in more support for the structure, but I think it’s about as good as it’s going to get.

I cut and installed the lower geodetic braces in the aileron, as well as the aileron skin support (not sure if the plans refer to it as a spar or not). I’m pretty happy with how this one is coming together, especially considering the angst the first one caused.

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Wing walk skins down

Today I went through more epoxy than I have since gluing the spar caps. After some sanding and test fitting, I pre-glued the wing wall structure and the two plywood skins. Then Stu helped me clamp the edges down, and pinned down any spots that weren’t firmly in place.

As planned, I used some scrap lumber to make clamping bars. I used strips of geodetic material between them and the skins to ensure good pressure and clamped everything together with bar clamps.

With some epoxy left over, I glued the nose spar onto the aileron and did a little more corner blocking on the wingtip bow supports. With all that clamped, pinned, and taped in place it was time for lunch!

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Aileron freedom – and wing walk work

Today I located and temporarily screwed the bearing blocks in, and cut the aileron free from the wing.

With that done, I decided to have another look at the wing walk situation. I don’t know why the support bits were the way they were, but I decided to just get on with making them work. When I look at the plans, especially the oblique view, indicate that the parts may have been cut in an attempt to match a much earlier version of the wing without much of the reinforcement at the main spar root. Anyway… Two of them had the aft end cut well enough to work at the rear spar. The inboard support needed to be trimmed at both ends. All had to be modified to fit the main spar.

In the end I got all three to fit, though I’m not terribly thrilled with the lack of good options for supporting and blocking the ends.

Next up were the notches for the cross braces. Most were too shallow and look to have been cut out with an end mill or router; the corners were rounded. I used a file to square up the corners and deepen the notches to fit the 1/2 x 3/4 pieces.

I figure I’ve got another hour or so of work to get all of the blocking and support in place before mixing epoxy. Probably more; I still haven’t figured out what I’m going to do about the extension of the walk forward of the main spar. If I build it to plans I’ll need to remove or hack up the first false rib. And of course the plywood pieces require significant modification.

On the bright side, the plywood skin for the wing walk curves nicely and won’t be a problem to get glued down. I’d been worried about that, and had visions of needing to make my own laminated piece there, but it’s fine.

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Same thing, different side

Today I went over and flipped the wing right side up, which is pretty easy to do with that nice big curved handle on one end. I cut and glued in the same bracing I did the other day, this time on the top side of the wing. It went pretty quickly.

Tomorrow I’m hoping to get the torque tube bearing blocks screwed in place and cut the aileron free from the wing. We’ll see how that goes.

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Aileron end plates, blocking, tip supports

This morning I woke up early and couldn’t get back to sleep, so I headed over to get a little work done. I glued and clamped the aileron end plates (CW34) in place, along with the corner blocking for them. I also did a little work shaving off some of the excess plywood and corner blocking on the wingtip bow. I’ll probably just have to switch to some low-grit sandpaper to get that job done. I’d really like to get the plywood gussets cut and glued in — oh, wait, there’s more bracing for the wingtip bows to be done…

This afternoon I figured that after 8 hours or so it was safe to move on. I made another trip over and cut and installed the CW40 plywood stiffeners for the aileron and each end of the aileron bay. Then I cut and glued in supports for the wingtip bow. All of this is just the bottom side — since the wing is upside down. I’ll do the top side once I flip the wing back over, which will likely be tomorrow.

Getting two work sessions per day in could really speed things up. I think I’ll try and do more of that. I’m not thrilled with the fact that I seem to be averaging only three days a week working on this — I need to get a fire lit under things, figuratively speaking.

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More CW35s glued in

I may be taking too cautious of an approach here, but I really don’t want to have to do a lot of work on the aileron ends like I did on the first one. carefully measured and cut the trailing edge so I could put the CW34 aileron end plates in place. Then, with the CW34s clamped in to make sure the edges lined up with the ends of the aileron spar, I lined up and glued in the pairs of CW35 pieces on each end of the aileron. I have the AL tubing in place to keep everything perfectly aligned.

I’ll probably go back and glue in the CW34s later on tonight. I probably should have just done it this morning. I get a little paranoid about this part of the process, since I’ve had to adjust or re-cut most of the holes for the torque tube.

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More aileron structure

Getting the CW35 aileron nose ribs located perfectly in the aileron is critical to making sure the aileron is straight and consistent with the other wing. Today I slid the torque tube into place and checked the fit of all the pieces that I can at this point. After making some adjustments to the holes in the CW36 end plates, I glued the three CW35s in place in the middle of the aileron. The next step will require cutting the trailing edge to install the aileron end caps, so I want to make sure the torque tube location is easily and consistently reproducible.

I think at this point I may just bolt the torque tube bearings in place (I have a set of 3D printed temporary pieces) and cut the last piece of AL tubing in half. This will let me work with a much shorter and easier to handle piece of tubing while setting up the ailerons.