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27-11 Ailerons (LD)

Builders Guide

27 Flight Controls

27-11 Ailerons (LD)

Link to the Builders Database for the aileron sub-assembly..

Tools Required
Aluminum Channel or Angle
Pop Rivet Gun
Drill
Drill Bits, #30, #40, 3/16, 1/4
1/8 copper Cleco’s (50)
3/16 brass Cleco’s (4)
Cleco pliers
V Block Drilling Guide
Tape Measure
Magic Marker

Parts List (Left and Right Ailerons)
27-11-12 TE Splice 1                                       (4)
27-11-13 TE Splice Outboard                          (4)
27-11-20 Splice Tube                                       (2)
27-11-21 Inboard Reinforcement Tube            (2)
27-11-22 Reinforcement Tube                         (4)
27-11-23 Outboard Reinforcement Tube         (2)
27-11-65 Trailing Edge                                    (2)
27-11-66 Trailing Edge Inboard                      (2)
27-11-67 Trailing Edge Tip                             (2)
27-11-70-01 Aileron Spar Inboard                  (2)
27-11-70-02 Aileron Spar Outboard               (2)
27-11-81 Rib #1                                              (2)
27-11-81-01 Rib #1 Mirror                             (2)
27-11-82 Rib #2                                              (2)
27-11-82-01 Rib #2 Mirror                             (2)
27-11-83 Rib #3                                              (2)
27-11-83-01 Rib #3 Mirror                             (2)
27-11-84 Rib #4                                              (2)
27-11-84-01 Rib #4 Mirror                             (2)
27-11-85 Rib #5                                              (2)
27-11-85-01 Rib #5 Mirror                             (2)
27-11-86 Rib #6                                              (2)
27-11-86-01 Rib #6 Mirror                             (2)
27-11-87 Rib #7                                              (2)
27-11-87-01 Rib #7 Mirror                             (2)
27-11-88 Rib #8                                              (2)
27-11-88-01 Rib #8 Mirror                             (2)
27-11-89 Rib #9                                              (2)
27-11-89-01 Rib #9 Mirror                             (2)
27-11-90 Rib #10                                            (2)
27-11-90-01 Rib #10 Mirror                           (2)
27-11-91 Rib #11                                            (2)
27-11-91-01 Rib #11 Mirror                           (2)
27-11-92 Rib #12                                            (2)
27-11-92-01 Rib #12 Mirror                           (2)
27-11-93 Rib #13                                            (2)
27-11-93-01 Rib #13 Mirror                           (2)
CCP-4-2 Rivets                                         (408)
27-10-31 Aileron Control Horn                     (2)
AN43B-20A Eye Bolt                                    (8)
AN3-20 A Bolt                                               (4)
AN365-3 Nylock Nut                                     (4)
1/4-20 Nylock Nut                                          (2)
AN960-10 Washer                                          (8)
AN-960-416 Washer                                      (10)

Assembly Instructions

Notes:
1.   Refer to the builder database for the most recent and up-to-date drawing files.

27-11-70  Aileron Spar (LD)

27-11-70  Aileron Spar (LD)
The aileron spar sub-assembly  page should be referenced for building the aileron spar  before beginning the rest of the  aileron assembly.

Link to the aileron spar assembly instructions

We can go ahead and prepare each one of the aileron rib halfs by deburring both the rivet holes and the edges of the rib.

We will be drilling only 1 of the 2 holes for each of the rib positions. We will mark and drill  the hole that is closest to the inboard section of the aileron spar for each rib position. We will be marking along the line located on the bottom of the aileron spar. We will be installing the bottom half of the ribs 1st and then adding the top half after all the bottom ribs are in place. The rib positioning holes are 90° to the eye bolt hinge holes that were installed during the aileron spar subassembly construction.

Once we have the rib positioning holes drilled we can start to assemble the aileron. Place each rib in position with one Cleco.

We will then position each rib with a combination square to ensure that it is 90° perpendicular to the aileron spar.

Then while we are holding the rib perpendicular to the aileron spar we can go ahead and drill the 2nd rivet hole. At this point add a 2nd Cleco the rib in position.

Once all of the lower ribs have been installed with 2 Cleco’s we can now attach the top half of the rib to each one of the lower rib halves.

We will not be Drilling the holes for the top rib have until a later period of time. Because each one of the rib halves have been previously deburred, you can go ahead and rivet the 2 rib halves together using 4 – 2 stainless steel pop rivets.

Once all of the top and bottom rib halves have been riveted together we can now attach the bottom rib to the main spar. Remember we will not attached the top rib to the spar at this point.

Although a hand rivet gun is more than adequate for this task a pneumatic rivet gun makes the process much easier.

Next we will position the trailing edge. We can refer to the drawings for the positioning of the trailing edge. We will be using rib #4 and rib #12 to position the trailing edge material in place.

The actual placement of the trailing edge material should be position so that the leading edge of the trailing edge material should have about .02″ to .06″ Clearance between the web of the #12 and #4 ribs. This will allow us to rivet each of the bottom half of each rim to the trailing edge material and still allow for some flexibility for final positioning when we flip the aileron over for drilling and riveting of the other side.

Referred to the aileron assembly drawing for the cut angles on each of the trailing edge pieces. The trailing edge should be cut so that the intersection falls directly between the 2 rivet holes of rib #12, and the same thing should occur on rib #4.

Once we have positioned rib #12 and rib #4 We can place a straight edge along the trailing edge material or simply sight down the length Of the trailing edge to ensure that it is straight. The trailing edge material is formed in such a fashion that it has a tendency to remain very straight. However this is very lightweight material and can be easily deflected if you put too much pressure during the drilling process. Using a straight edge or the edge of the workbench will help ensure that you retain a nice straight clean line.

You can now use a piece of straight edge material resting on the aileron spar and position the trailing edge material up flush as you drill each of the holes for the rib attachment. You can drill Both holes in each of the ribs Cleco it in place and then move on to the next rib.

After the trailing edge material has been cut and trimmed to the proper dimensions and all the holes drilled for the ribs on this side you can go ahead and Rivet each one of the ribs to the trailing edge material using 4 – 2 stainless steel pop rivets.

Once again we are using a piece of straight edge to ensure that the trailing edge material remains straight during the construction process.

Keep in mind before you rivet rib #4 and rib #12 that you will have to be inserting a trailing edge splice. This splice can be placed on the top, or you can place it in the recommended position inside of the trailing edge material so that it is no longer exposed and causing extra drag. Either way the splice should be positioned on the outside to use as a guide for the rivet holes which can be drilled through both sections of trailing edge material. The splice uses the 2 holes located in the rib as alignment holes.

Cleco the splice plate to the rib to use it as a guide for drilling the 2 trailing edge pieces on either side.

In this picture here we can see the final disposition of the trailing edge splice being riveted permanently after being positioned on the inside of the trailing edge material.

We do not need a line on the top side of the spar to rivet the aileron ribs. We will be using a number 40 drillbit in between the web of the rib and the main spar to provide clearance. This will properly position the rib so that we may have clearance on the outboard ribs to provide washout. So once again we will position the #4 rib 1st and then we will proceed to the #10 Rib Pl. the number 40 drillbit in between the web and the spar then drill and rivet in place. This now provides us a fixed position from which we can position all of the other ribs onto the spar.

By placing weights along the length of the aileron assembly on a perfectly flat table we can ensure that the rib positioning remains without any twist Between rib #4 and rib #10. Drill and rivet the ribs to the spar and then proceed to drilling the ribs to the trailing edge material. Work on only ribs #4 through #10. Ribs 11, 12, and 13 will be tweaked upward to provide washout. Do not drill or rivet ribs 11, 12, and 13 at this point.

Next proceed to rib #13. We will be holding the rest of the aileron down with weights and positioning the very outboard rib, rib #13. The trailing edge of rib #13 should be position 1 inch up from the table with the rest of the aileron flaps against the surface.

You can also now attach the trailing edge to the upper rib with 4 – 2 stainless steel pop rivets.

We can now go ahead and attached the trailing edge to ribs #12, and #11. We will wait to drill the holes for these ribs into the spar until after we have completed the trailing edge. Remember that rib #12 will have another splice plate installed on this side as well. This is going to take a bit of patience because there is virtually no clearance left in between the splice plate and the other rivets sticking through the adjacent side area. Normally you will have to carefully which a straight slot screwdriver in between the rivets and provide enough clearance to be able to pull the pop rivets on this side.

The same process should happen on the inboard section of the aileron with rib #1, #2,  and #3. The only difference here is that there is no washout on the inboard section and it should be installed centered with the main section of the aileron.

With the aileron complete without the hinge eyebolts and the aileron control horn.

Total weight came in about 5.4 pounds.

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About Brian Carpenter (255 Articles)
CEO Rainbow Aviation / Adventure Aircraft

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