Only four rivets set today but it feels great to start closing the ailerons


Last prep before riveting Ailerons together

Might have some final drilling left to do but otherwise it is finally time to rivet again. Countersunk the trailing edges, smoother the skin edges and then scuffed the surface before priming.



Getting closer to finishing the ailerons

Dimpling, edge breaking and more dimpling. Grinded the edge off one of my squeezer yokes to be able to dimple the ribs.


Close call, Aileron

Almost made a big mistake tonight. Read about it in the picture comments.

Skin is good

Attaching the trailing edge

On one side the edge is flush with the skin on the other it is showing about 1mm, measuring skin hole to edge distance and A-1011 hole to edge distance


And measured again

marking and taking pictures with the intent to ask on VAF forum...

Calculating and the numbers do not make sense! Opposite result compared to my logic... this cannot be, time to take a closer look at the parts

And I finally saw the problem, I had put the clecos on one Aileron thru the large lightening holes instead of the rivet holes!

Final drilling, I let the drill find the correct angle on itself and made sure not to try and make it 90 degrees towards the skin

Thens its time to take everything apart again for trimming, deburring, dimpling, countersinking and priming 


Aileron coming along great

A short session while my youngest had a nap


Aileron stiffeners all in place

Placing rivet

Securing rivets

Placing stiffener

Back riveting



Aileron skins are coming along great

deburring, dimpling, priming and started to back rivet the stiffeners.


Aileron continues

Remove plastic, deburr and dimple. Two aileron skins done.


Aileron skins

It is not foolproof regarding which aileron skin goes where so I decided to do a trial fit. Good thing because I got it wrong on the first try!

Yes, I´m using a screw driver to final drill

Here I¨m getting skeptical, it does not fit the same way on the right and left aileron

Holes are not close to lining up!

The secret to getting it right is that in addition to the remarks in the plan: realise that the hole spacing is smaller at the trailing edge

Much better!


32 Aileron stiffeners

Deburr, dimple, saw, grind... there are lots of them!


Aileron stiffeners

Started on the aileron stiffeners. Final drilling, cutting apart...


Aileron tinkering

Riveted some of the parts together. Must be careful to leave the correct holes unriveted. Then I spent what felt like a really long time, mounting the counterbalance to the front ribs, only eight screws in total but I only had room to make 1/6 of a lap on each take with the tools.

Dangerous countersinking! Great result tonight but lets stay away from this practice


Two really short aileron sessions today

First was a less than 10 minute session were I primed the other side. The a longer one were I decided to put all the ready parts together to make sure I will be right.


More aileron work

Some final drilling and prep for primer...


Aileron leading edges, continues

This post is for both yesterdays and tonight's work. In total I spent 1.7 hours match drilling the weight to the aileron ribs and skin. If I were to do it again it would probably take 0.3-0.4 hours.
Drilling the first two holes described in the first related step
Decided like others that there is no reason not to drill the rest of the holes at this time

Not to difficult but the drill bit needs to be sharp to handle the steel without slipping

This hole was just drilled enough to make a mark, I completed it on the drill press

#27 final drilling