Due to the 3-1/2" x 25-1/4" size of the ailerons, making the skins is going to waste a lot of balsa. I don't want to burn 4 sheets of nice 4" wide x 48" material so I'm going to have to cut up and join some of the 3"x36".
After making the lower skin, I made a template from the plans to create the curved shape at the tip. All the little ribs I saved in a small cup were trimmed and glued down to the 3/8" T.E. set back line.
I ordered a bunch of real nice Heavy Duty flat hinges from TBM. My gut tells me we need (5) hinges per aileron. This spaces the hinges 5-3/4" on center. Sound about right??
This Aileron is a pretty big Flapper... I'm not really fond of top hinging so I'm going to deviate from the plans and double bevel the aileron leading edges. This method puts the flat hinge in the meat of the wing instead of the top sheeting. Mo betta and stronger.
They are extremely flat, sharp, rigid and should never warp. I would describe the construction method but I'd rather not re-live it. Also got after the servo hatches and mounted a full car payment worth of servos. Still need to cut the slots for the servo arms.
Added 6-32 blind nuts to the gear rails and blocked off as much as I could to create the wheel well liners. The front of the wheel well was filled will expanding foam. The rear of the well was capped with 1/32" plywood along the edge of the sheeting and reinforced with glass from the inside to make everything solid.
I really wanted to sheet the tops of the wings but decided to take care of a lot of little things that are bugging me.
I in-layed a 1/32" x 1/2" wide plywood strip into the trailing edge of the wing panel to support the hinges and added hinge blocks to the inside of each hinge location. I carefully cut the 6 hinge slots keeping them straight and inline as possible. I have to admit these flap are really nice. They deploy real smooth with about 45 degrees of deflection.
This completes the bottom of the wings and they are ready to start the top sheeting process.
The 1/2" wide carbon cap I've been saving for the top of the main spars is going to lay down real nice under the top sheeting.
Spent a lot of quality time preparing and sanding the the spars, leading and trailing edges for the top sheeting to lay down real nice. The top carbon spar cap was inset and glued down. Everything is looking real good.