With all the components of the left aileron now primed, I can begin the final assembly and prep work. First step is to dimple the ribs, and the part of the skins where the ribs attach. Next I back rivet the ribs to the skins.
Once the skins are prepped, I can cleco the entire aileron together again to fit the trailing edge and get it drilled. I’m also checking to make sure there is no twist or weird waves in the aileron at this stage with a straight edge.
Once the trailing edge has been drilled, I once again disassemble everything. I also double countersink the trailing edge as the final prep step for the ailerons. Then it’s time to begin final assembly.
First step is installing the components into the nose skin. Ribs and counterbalance assembly is installed and riveted into place in the nose skin. Next I install the spar and rivet that to the nose ribs using blind rivets. If I didn’t mention it already, I really like that pneumatic blind rivet puller. So much better than the manual one.
With the nose assembled, I then install the top skin between the nose skin and the spar. For some reason I felt that my bench and the aileron were sitting just a little high for me to reach over the skin to rivet, so I decided to put the work on the floor and bend over it to rivet. Seemed like a good idea, but later my back told me that I was being dumb. Regardless, it worked and I was quickly able to get the top skin riveted into place.
Next up is installing the bottom skin. Same deal as the top skin, but you have to stick your hand between the skins to hold the bucking bar. It’s been a number of years since I have been described as “skinny” or “small” so I’m amazed that I could get my hands in there to correctly hold the bucking bar. (I did have to remove my watch and ring). I’m not going to suggest that every rivet was perfect, but they were within spec.
I then installed the trailing edge and checked that everything looked nice ans straight. Next was to install the blind rivets in the nose into the counterbalance. and to set the rivets between the hinge bracket and spar. These AN470 rivets were a pain and I ended up with a smiley or two. As much as I would love to replace those rivets and do a better job, my fear is trying to remove those rivets in that cramped space would end up doing more damage than good, so they will stay smiley and all.
Last step is to install the trailing edge. I decided to use the VHB tape as well as the cleaveland trailing edge squeezer tool. I clean all the surfaces with acetone, then install the VHB tape on both sides of the trailing edge. I then install the TE and cleco everything together and press the edges together so the VHB tape will help hold.
Next I use the squeezer tool to start setting the TE rivets using the special dies. Pretty easy and looks decent enough. I have a feeling that back riveting will net a better result, but it is what it is. Once the TE is all riveted, I install the last few blind rivets on the edges of the ailerons. With that the aileron is completed and ready to install on the wing.