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Section 4: Hinging and Sealing the Aileron Control Surfaces
Step 3. Allow the epoxy to fully cure for at least six hours.
When cured, work each hinge throughout its full motion several
times using your hands. This will break free any epoxy that may
have found its way into the hinge joint. Move the hinge through-
out its full travel until no resistance is left. This may take as
many as 40 or 50 times.
Step 4. Mix 1 ounce of 30-minute epoxy. Using a syringe or
toothpick, place a sufficient amount of epoxy in each of the hinge
pockets in one aileron half.
Step 5. Carefully insert the aileron on the wing, making sure the
hinges are inserted into their respective hinge pockets. Press the
aileron and wing together such that less than 1/64" hinge line
gap exists between the aileron and wing. The bevels should
virtually touch. Using a paper towel and rubbing alcohol, wipe
away any visible epoxy around the hinges.
Step 6. Double-check the hinge gap and allow the epoxy to fully
cure for at least six hours. Repeat the process for the other wing half.
Step 7. When the epoxy has fully cured, move each control
surface throughout its travel range several times to break away
any epoxy in the hinge. Be sure to deflect the surface fully.
Sealing the Hinge Gaps
It's imperative that the aileron and elevator hinge lines be sealed
airtight to prevent flutter. Sealing the hinge line has several
advantages. A sealed hinge line gives a greater control response
for a given control deflection. It also offers more precise,
consistent control responses and makes trimming easier.
Caution: Sealing the aileron and elevator hinge line is
mandatory. Failure to do so may cause control surface
flutter, resulting in a crash.
CONTINUED
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