Aileron Construction Sequence

Now that I've built four of these things, here's the sequence of steps that seems to work best. There might be other steps to consider - for example, I had to open up the trailing edge bend to drill and rivet the stiffeners and then had to rebend it. I also had to tighten up the leading edge radius a bit, too.

The plans said to use a flat table, but I use a couple of vee blocks, carefully aligned, just like I did when I was building the tail control surfaces. The vee blocks are also used for the flaps. It's a simple way if ensuring straightness.

Drill spar flange to top skin

Stiffener - Dimple

Stiffener - Prime

Stiffener - Rivet

Drill the spar's lightening holes

Rivet reinforcement plates to spar

Drill nose ribs to spar

Remove nose ribs, drill main ribs to spar

Cut access holes in inboard main ribs

Drill pipe to nose ribs -- manual says to spar.

Prime pipe.

Rivet pipe to nose ribs

Rivet nose/main ribs to spar

Break bottom-most edge of skin

Place in jig

Tape and clamp skin in place

Locate bottom spar holes

Check

Drill (#40) bottom skin and spar, cleco

If the leading edge radius needs rebending, do it now

Drill skin for end ribs

Drill pipe balance and skin

Disassemble, prime and deburr and dimple

Rivet top of spar to skin

Clean out any debris from interior

Replace in jig

Blind rivet (CS 4-4) the bottom of skin/spar

Rivet end ribs, pipe balance

Trim leading edge at outboard ends for hinges

Dave