06/09/2008 - Flap and Aileron braces & Aileron brackets

Now that the wing is the other way up the braces and brackets can be fitted.  For some reason I struggled in my head to this as I am doing the right wing first and the plans show the left one, I could not sort it in my head how to reverse it all.  I ended up clecoing the left hand brackets together so I could not get the right ones wrong !

Other than that it all went fairly straight forward.

Belcrank time

The first picture shows why I stormed out of the garage in a tantrum.  There is no way the bolt we go through the brackets in the spar to hold the belcrank while they are bolted onto the spar !!!!!!  I must of been tired cause I forgot that they were just nut plates on the end of these so they could be removed.  For a good ten minutes I was convinced it all had to come apart again !!

Anyway removed the brackets and cleaned up the surfaces to get rid of the original Duralac that was used in between the spar and the brackets.

The brass bushing has to be filed to size, and then drilled out to accommodate the bolt.  A little research showed people having difficulty with this; some using 1/4" chucking reamers but I did not have one of those.  What I did have was a 1/4" drill that will be used to drill the hole in the horns on the empennage.  Basically it has a pilot and cutting end then a straight shank that would go through the bushing.  So I decided I could use this as the tool to drill out the centre of the bushing.  It went reasonable well with boelube and taking a little time over it.  Had to use the electric drill as the air drill would not handle it.

The section that holds the large push rod also has to have an aluminium bushing made to the correct length, which I used a pipe cutter for.

Used copper slip on the brass bushing when it was assembled.