Covering: Ailerons

Finally got the ailerons done. Process is identical to flaps. First pic shows fabric fastened to leading edge with clamps, in preparation for notching fabric at rib locations.

Next pic shows fabric glued to leading edge and then another coat of glue applied for bonding of other fabric end to LE.

Below are completed ailerons. Now onto elevator and horizontal stabilizer control surfaces.

Covering: Flaps

I completed covering both flaps this weekend, which began on New Years Eve. The process will be similar to the ailerons and involves gluing fabric to leading edge, then wrapping around trailing edge and gluing to leading edge. Fabric overlap on the ends is then folded over and glued. Once fabric is secured on all sides with glue, the fabric can then be ironed and tautened. A drain grommet is installed on the inner bottom lowest point of the control surface. A grommet is just a small plastic looking washer which is glued to the fabric. A 2" patch is glued over it and later a hole will be burned through the grommet with a heat knife. Several other patches were glued to the flap where fasteners will penetrate through holes in the flap. End patches were fabricated and glued on. Then 2" tape was glued on LE and TE. First pic below shows masking tape placed on sharp part of ribs. The forward and aft part of ribs were smashed down and then smoothed with a dremel wire brush bit. Important to either tape over or smooth out any sharp points which could tear fabric. First pic shows base coat of concentrated glue on metal, then application of dilute adhesive being brushed over fabric to dissolve underlying glue and pull up through fabric matrix. Talking with Rans, I've begun applying two coats of concentrated U500 instead of one heavy coat. Surface prep cleaning of metal consists of naptha and then scotchbrite. The latter helps scratch the metal and enhance glue bonding.

Below pic shows completed flaps finished with tape. I punched holes where appropriate with an awl now as finding them later following painting will be difficult. Straight MEK works well cleaning up any glue off fabric which I'm told will be visible following paint.

I've been breathing the vapors in a closed garage so far (hard to justify opening garage door when 10 degrees outside), but after a long day yesterday I've had a persistent headache. Will begin using a supplied-air setup which I had purchased for later painting.

I've thrown away the razor blades for trimming fabric, as I had to redo a door earlier after tearing finished surface. A good pair of small sewing sizers (like used for fly-tying) works will for trimming excess fabric on glue joint. I've also learned to forego using a sharpie to mark lines on fabric, as MEK will dissolve and bleed. Soft lead pencil works great. A black and decker electric shears works great for cutting large pieces of fabric off the roll.