Tuesday, April 25, 2006


The cable then attaches to this aileron bell crank. An arm will extend back through a hole in the back of the wing to operate the aileron. Is this really the way the Wright Brothers did it?

To operate the ailerons, a cable will pass behind the wing and go over the pulleys which extend below the wing...then up to the pulleys which are inside the wing...through the hole in the wing rib...

The ailerons are suspended from these two hinges.

This is the bellcrank that will operate the flaps.

Here are the two flap tracks...looking inboard.

Most of the components that need to be attached to the basic wing structure have now been corosion proffed and reassembled. This is flap track seen from the bottom of the wing looking outboard.

Sunday, April 02, 2006


Here is the inboard flap track...another one is further out on the wing.

Here the assembly is mounted on the aft spar of the wing.

The flaps move on a track. The track is joined to a supporting bracket on both sides...#30 holes are drilled (at the + marks) through the whole assembly.

Here is another bracket that I made supporting the double pulleys that will operate the aileron bellcrank.

The rough cut piece on the grinder, ready to be cleaned up.

Here I am making bracket from a piece of aluminum angle.

Some pieces have to be fabricated from stock aluminum. This is a great tool for this...the handy-dandy band saw ($99) at Home Depot. I used to cut metal out with a dremel tool...this is much easier.

These are hinge brackets which are also 3 part assemblies from precut pieces. I have drilled all of the holes that will hold this together and mount it to the wing. Of course, it will have to be disassembled and treated with corrosion proofing primer.

Now it starts getting fun again. It's time to fabricate/assemble all the moving parts that operate the ailerons and flaps inside the wing. This is the aileron bellcrank. It is assembled from precut pieces.

You havn't seen a lot of pictures lately...partly because I have misplaced my digital camera...and partly because our 'empty nest' got full again so we've doing other things. Earlier you saw the left wing coming together. A lot of time is spent getting everything just so...and then drilling 10,000 holes. Then just when it really looks like something, you have got to take it all apart again. All the holes have to be deburred. Everything has to be cleaned with aluminum cleaner and then treated with Alodine to prevent oxidation. Then the lovely green primer gets sprayed on. Well all that finally got done. Here's the wing going back together again.