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Building Integrity
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Date:  9-27-2013
Number of Hours:  7.00
Manual Reference:  ch 25
Brief Description:  Control surface fill and fit

A lot of time spent filling and contouring both the rudder and Aileron. I found that to get both trailing edges of the aileron to flush with the wings' trailing edge, I needed to put somewhat of an odd filler contour on either side of the aileron. Strange because it's almost as if there is a twist in the aileron that developed somewhere along the way. Instead of trying to heat it and twist it I am going after a filler fix on this one. I also had to add 2 plies of BID to the outer most hinge attach point and 1 ply in the center. I sanded these areas doing in an attempt to flush both TE's before realizing the twist issue. Therefore they are being built back up again. I have got the aileron within 1mm of being flush and am hoping that after applying primer I can get the last bit of contour just right. I was also able to remove over 2oz of filler helping the aileron balance a little better. It's crazy how narrow the margin is in balancing these ailerons.
The rudder required a few stages of filler application and I went ahead with a skim coat due to the exposed fiberglass. After skim coating I noticed a low spot in the reflection which will give me a great reference for adding filler again. NO skim on the ailerons in order to keep weight down.
Finally, the drainage hole in the wing bolt access was drilled and tubing was installed. This time I used thick superglue instead of micro which made a much faster and cleaner installation.
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rudder filled and skimmed

rudder filled and skimmed

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2 ply bid pad added

2 ply bid pad added

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drainage hole

drainage hole

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