Attaching Ailerons to the Wing

I completely finished the flaps and ailerons before I mounted them to the wing.

I positioned the wing, with the leading edge and the top main skins riveted on, in the wing cradle, leading edge down.

I assembled the aileron pushrods, priming both of them inside and out. I covered the inside by spraying into each end. I then riveted the rod ends to each pushrod.

Making sure the primer was fully cured, I then threaded the rod-end bearings and jam nuts on. I temporarily taped the pushrod where it passed through the rear spar, so when aileron was removed the primer wouldn’t be scraped away.

I install the bellcrank. The bushing in the bellcrank needed to be drilled to final size for the slip fit on the AN4 bolt. The bushing needed to be slightly longer than the aileron bellcrank. It was held firmly between the bellcrank brackets with the bolt. The bellcrank rotated around the bushing, not the bolt. This is the same way that the stick assembly would be done also. I lubricated the bushing with grease when assembling for the final time.

I connected the pushrods to the bellcrank. I used the bellcrank jig provided to set the bellcrank in the correct neutral position. I used a plumb line to position the aileron in the neutral position. I clamped the aileron in this position and adjusted the rod end bearings on the push rod until the pivot bolts at the bellcrank slipped in smoothly. I tightened the jam nuts and labeled the push rod right or left as appropriate. Final adjustments would be made to the second push rod later, when the wing would be installed on the fuselage.

Time: 8 hours.