Aileron Leading Edge

The aileron leading edge is much more difficult to install than the wing leading edge.  Reason?  The aileron leading edge must be bent around a smaller radius.  It take quite a bit of force across the 4 foot wide sheet of aluminum to get it to bent that tight.  One solution: get a couple of helpers and use 4 to 6 hands at once to bend it around.

But if you're like me (working by myself most of the time!) you'll need to use this little trick.  First, tack the leading edge to the spar along the bottom of the aileron.  Use those little 3/8" aircraft nails in the spar and a few #4 screws into the ribs.  Then bend the leading edge part way around and tie it in place with a 2' length of 1/4" nylon rope.  Move a little further down and do the same thing again.  (Photo 1)   Continue bending and tieing until the entire leading edge is partially bent.  (Photo 2)   Add a row of screws to hold it in place, then bend it a little more and tie it again...add more screws.  Bend, tie, screw...bend, tie, screw...until it's done! 

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Aileron Assembly

Procedure for assembly of the aileron:

1. Transfer the rib locations, reinforcement locations, and hardware locations from the old spar to the new spar.  Glue and nail the center reinforcements onto the new spar.  Varnish everything except the inboard and outboard reinforcement locations.

2. Slide the ribs onto the spar. I use the vertical wing assembly jig with the uprights moved closer together. (Photo 1)  Leave them loose for now.

3. Glue and nail the inboard and outboard plywood reinforcements onto the spar. (Photo 2)

4. Varnish the plywood reinforcements.

5. Double check the hardware locations using a machinists square and tape measure.  Mark the hole locations onto the reinforcement plates.  (Photo 3)

6. Use the drill press to accurately drill the hardware locations.  (Photo 4)

7.  Bolt the hardware back onto the spar, nail ribs in place, re-install the trailing edge and tip bow.  (Photo 5)

8. Flip the aileron over and nail the nose ribs in place.  Use a third-hand square to hold the ribs while you nail them.  (Photo 6)  And finally, screw the leading edge pieces back onto the nose ribs.

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Buying a Project Plane

Some tips on buying a Project Plane:

(1) Buy a plane made in the great post WWII airplane boom...1946 was a great year for light planes.  Thousands of sturdy, docile little civilian planes were produced at this time.  They all followed the same formula: fabric covered taildraggers with plenty of wing, sturdy wing struts, no electrical system, and powered by the famous, classic, super reliable Continental A-65 engine.  Piper, Aeronca, and Taylorcraft are some of the better known brands.  Through the years these wonderful old airplanes have been extremely well maintained, as an aircraft must be, and thousands are still available at very modest prices.

I recommend the Taylorcraft (Photo 1).  The T-Craft is a great bargain.  Although prices are trending upward, project planes are currently selling for less than $10,000.   (I bought an all-there T-Craft project two years ago for $8000 that included a 0-time Continental engine)    The Taylorcraft is known for its docile, beginner-friendly flying qualities and its simple low-tech construction is ideal for home shop restoration.

(2) Buy a non-flying project.  You'll be tempted to buy a flying-but-needs-restoration bird...but you'll pay twice as much for it and get maybe a year or two, at most, of flying before you have to tear it down for rebuild.  Get a plane that's been in storage for a few years and use the money you save to give her a first class restoration!

(3) Go get it yourself.  Don't attempt to have your project shipped to you.  A car trailer can easily transport a light plane with the wings off.  (Photo 2)  If you're only going a short distance, you can even tow the plane on its own wheels. (Photo 3)  You'll save a bundle by acting as your own trucker, and when you go to pick up your project you can be certain to get ALL the parts.

(4) On any given day, dozens of projects are available online at eBay, Barnstormers and at Trade-A-Plane.  Also, a good source of project planes are type clubs like the Taylorcraft Foundation and local EAA chapters.

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