Continuing on with aileron work, I started to prepare the aileron nose ribs for attachment to the hinge brackets. Since most holes are already final sized, I just had check all flanges for alignment, upsize the #12 holes (using a reamer) in the inboard hinge brackets and ribs, countersink the relevant hinge bracket holes, debur all holes and edges, and dimple the necessary nose rib flange holes.
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| Aileron nose ribs ready to be worked on |
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| All parts marked and ready for drilling and countersinking |
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| #12 holes and countersinks were done with the pieces held securely in the vice |
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| Countersinking the hinge brackets using a jig with a pilot hole to prevent the countersink from chattering |
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For the outboard hinge brackets, I placed them side-by-side while countersinking to make it easier to hold the countersink cage perpendicular to the bracket, without it tipping over the edge which would cause an uneven countersink
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Next I finished deburring all edges and holes, and also removed faceting on the inboard nose rib flanges using the deburring wheel. I then dimpled all #40 rib flange holes except for the two on the nose ribs that will attach to the steel counterbalance later.
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| All #40 holes dimpled in the nose ribs, except for these two at the front that will screw to the counterbalance tube |
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| All aileron nose ribs prepped and ready for priming |
I then took the aileron main ribs, A-1006 and A-1007 parts, and clecoed them together per the plans. This allowed me to make sure that all parts were oriented correctly prior to drilling. This exercise was especially useful because the plans only show the left aileron, and the right aileron is a mirror image.
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| Aileron main ribs and parts clecoed together and marked for orientation as well as countersinking |
Next I separated the main ribs, deburred all parts, and countersunk the A-1006, A-1008 and A1008 parts for the required rivets. I also reamed the #12 hole in the A-1007-1B pieces, and then countersunk the hole for a #10 screw. I ended up using the deburring bit to countersink the screw holes by hand. I initially planned to use my #10 countersink bit for this, but the pilot requires a #10 hole, so it did not fit into the #12 hole. Countersinking by hand worked well though and the test screw fit nicely through it.
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| Aileron main ribs and parts ready for priming |
After priming all the aileron rib pieces, it was a quick job to rivet the parts together using the pneumatic squeezer and longeron yoke, taking care to leave open holes where the two rib halves connect as they will be riveted later.
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| Shop heads formed nicely, I just had to be careful to make sure the squeezer yoke was held securely during the squeeze. I had to drill out and replace one rivet because the flat set did not cover the entire rivet shank causing it to deform while squeezing. |
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| Manufactured heads sit flush in the countersunk holes |
Dates: May 5 - May 11, May 21 2024
Aileron Total Time: 10.4 hours
RV-10 Build Total Time: 674.8 hours
Priming Total Time: 80.0 hours (not included in build time totals)
