Continuing to assemble the right aileron, I start to rivet the hinge brackets together as I work on the top skin. I then continue to rivet all the ribs and the inboard and outboard brackets to the top skins per the plans.
I then disassemble the counterbalance and begin to attach the counterbalance to the ribs. While not mentioned in the plans, this is SO MUCH EASIER if you just remove the nose ribs from the spar before you begin to attach the counterbalance. This allows much better access with a screwdriver and small wrench.
Next I reassemble the nose section so I can pilot the nose skin to counter balance holes, then up-drill them to #30 to accept the blind rivets. Honestly I feel like I assemble, disassemble way too many times in this project.
Also I realized I dimpled the aileron skins before I should have. Only where the ribs are back-riveted should the skins have been dimpled. Spar and trailing edge should not be dimpled yet. (I’ll remember for the left aileron). Plans are accurate, but sometimes making sure you understand what they are saying can be a challenge. Either way, no big deal and totally was able to work past this bump.
I then completely re-assemble everything to drill the Trailing edge (checking to make sure the aileron is not twisted). Then take it all apart for hopefully the last time. I also left in some footage of me drilling the trailing edge with my drill jig. Easy to do with the drill press and a microstop cage.
I also decide to make cradles for the ailerons to help with assembly. You need to make them for the flaps anyway, so I guess making them early isn’t a bad thing.
With everything finally primed, I am able to start final assembly. I know it was in the flaps update, but I was jumping between flaps and ailerons for the last month. In this timelapse, I open and get to use the blind rivet puller for the first time. I think this was from Aircraft-tool? Not terribly expensive (not rated for cherry max rivets), but seems to work quite well. Highly recommend that you get one from any of the vendors.
The remainder of the assembly is straight forward. Only comment is trying to rivet between the hinge brackets is a pain in the rump. Got it all riveted together, but not getting any awards on those rivets. I did sand down one of my rivet sets a bit to allow it to physically fit in that tight space. Not sure how others did it as it’s really tight.
End of the assembly got lost to the camera gods. I am setting up to back-rivet the TE for the ailerons but guess the gopro lost power.