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RV-7 Construction Log
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Date:  1-26-2013
Number of Hours:  9.00
Manual Reference:  pp 7-10, 11
Brief Description:  Right Aileron

I started out by dimpling the right aileron main spar, nose and main ribs, and nose and main skins. I countersunk the holes in front side of the counterbalance pipe, and touched up those countersinks with primer. I also countersunk the front side of the aileron hinge bracket reinforcement plates on the spar for countersunk rivets to attach the main ribs. Riveted nose ribs to counterbalance pipe, and clecoed that assembly into the nose skin. I then riveted the main spar to the nose ribs. I had to do this TWICE, as I riveted the spar on upside down the first time. :O(

I then clecoed and riveted the main skin to the spar, leaving out the end ribs and topside clecos for access to the interior of the aileron with my small tungsten bucking bar (Photo 1). I then riveted the top of the nose skin to the nose ribs, followed by riveting the main ribs to the spar and the top side of the main skin. I then used a #30 male dimple die in a rivet gun set drilled to accept it to dimple the nose skin into the countersinks in the counterbalance pipe.

The aileron is still a bit flimsy at this point, so to help ensure a twist-free asssembly, the instructions have you weight it down on a flat surface before riveting the skins to the counterbalance pipe and the bottom of the main spar (photo 2). After installing all of the pop rivets, I finished up by riveting the bottom of the skins to the main and nose ribs, and installed the hinge brackets, torqueing and sealing all the fasteners.

This aileron is DONE!!

Rivets Today: 158
Rivets Total: 6576
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Riveting top of right aileron

Riveting top of right aileron

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Weighted  down on a very flat surface for riveting the counterbalance and bottom skins to spar.

Weighted down on a very flat surface for riveting the counterbalance and bottom skins to spar.

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Done, including hinge brackets.

Done, including hinge brackets.

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