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Richard Pike
Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee
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 Posted: Tue Mar 23, 2010 6:25 pm Post subject: FSII rebuild - aileron hinges |
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Update on the rebuild of the donor wing that came back from Florida to rebuild the FSII. Used the original tip gussets, and even though the holes were not well aligned, used them instead of trying to make new ones, since the rivet holes were not wallowed out and everything could be made to fit well.
But there was a more serious problem: the old aileron hinges were missing, and from the looks of the drilled out rivet holes, it is not hard to imagine why. Some of the holes are wallowed out to 5/32", oblong, etc. Thought about trying to match drill all the holes and go to 5/32" rivets, but that sounded like an awful lot of work for meager rewards.
Decided instead to just relocate the hinge closest to the wing root, move it in a few inches to a new spot, forget using a center hinge and use two additional hinges spaced evenly in between the inboard hinge and the tip instead, but the wing tip hinge itself was a bit more problematic. You can't really move the hinge elsewhere, you have to keep it where it belongs. So I copied Vince Nicely's method of using double loaded hinges that go in two directions, that way even if your tubing is a bit Swiss cheesed, you still spread the load around pretty well.
One normal sized hinge in the middle, holes spaced to fit between the original holes (gag - hate it, but what can you do?) and then a smaller hinge at either end going to the other part of the tube to eliminate flex bending of the hinge and add support to the whole arrangement. Not the ideal way, but ideally - the airplane would never have been rolled up into a ball last year and none of this would be happening. <grin>
Richard Pike
MKIII N420P (420ldPoops)
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Thom Riddle
Joined: 10 Jan 2006
Posts: 1597
Location: Buffalo, NY, USA (9G0)
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| Posted: Wed Mar 24, 2010 4:12 am Post subject: Re: FSII rebuild - aileron hinges |
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Richard,
I'm glad you posted photos because your prose did not paint an accurate picture in my mind (my mind's fault I'm sure). Looking back at the description of what you are doing AFTER seeing the photos makes the words make sense. Sure am glad we have a digital world today that makes all this so easy and cheap.
do not archive
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_________________
Thom Riddle
Buffalo, NY (9G0)
Don't worry about old age... it doesn't last very long.
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slyck(at)frontiernet.net
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| Posted: Wed Mar 24, 2010 5:04 am Post subject: FSII rebuild - aileron hinges |
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Was that done with a "Tennessee Straight edge"?  Will you pull (aluminum) rivets into the empty holes for cosmetic reasons?
BB
do not archive
On 23, Mar 2010, at 10:25 PM, Richard Pike wrote:
| Quote: |
Update on the rebuild of the donor wing that came back from Florida to rebuild the FSII. Used the original tip gussets, and even though the holes were not well aligned, used them instead of trying to make new ones, since the rivet holes were not wallowed out and everything could be made to fit well.
But there was a more serious problem: the old aileron hinges were missing, and from the looks of the drilled out rivet holes, it is not hard to imagine why. Some of the holes are wallowed out to 5/32", oblong, etc. Thought about trying to match drill all the holes and go to 5/32" rivets, but that sounded like an awful lot of work for meager rewards.
Decided instead to just relocate the hinge closest to the wing root, move it in a few inches to a new spot, forget using a center hinge and use two additional hinges spaced evenly in between the inboard hinge and the tip instead, but the wing tip hinge itself was a bit more problematic. You can't really move the hinge elsewhere, you have to keep it where it belongs. So I copied Vince Nicely's method of using double loaded hinges that go in two directions, that way even if your tubing is a bit Swiss cheesed, you still spread the load around pretty well.
One normal sized hinge in the middle, holes spaced to fit between the original holes (gag - hate it, but what can you do?) and then a smaller hinge at either end going to the other part of the tube to eliminate flex bending of the hinge and add support to the whole arrangement. Not the ideal way, but ideally - the airplane would never have been rolled up into a ball last year and none of this would be happening.
Richard Pike
MKIII N420P (420ldPoops)
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=291513#291513
Attachments:
http://forums.matronics.com//files/hng1_935.jpg
http://forums.matronics.com//files/hng2_169.jpg
http://forums.matronics.com//files/hng3_503.jpg
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Richard Pike
Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee
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| Posted: Wed Mar 24, 2010 5:34 am Post subject: Re: FSII rebuild - aileron hinges |
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| slyck(at)frontiernet.net wrote: | Was that done with a "Tennessee Straight edge"? Will you pull (aluminum) rivets into the empty holes for cosmetic reasons?
BB
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I knew this would happen...
The wandering row of rivets in the gusset were already in the gusset when I pulled it out of the parts box that came with the basket case wing, and it seemed better to put the original gusset back in place and refill the original holes than to make more holes just to have things straight and proper.
Will probably not refill the left over holes, they will be covered by at least two layers of fabric anyway, you won't see them.
It is what it is, a donor wing that will end up being airworthy. And after it's painted, all will be forgiven. (Or at least hidden...)
PS: Sorry I didn't have any way to take a picture of Steven Greene's MKIII before it was covered. His Tennessee straight edge must have been a laser, never saw such pretty rivet rows in my life. You could sight down the inside of his main spar or anywhere else and just feel unworthy.
Richard Pike
MKIII N420P (420ldPoops)
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