Pre-war welded aileron hinge fittings

[Robert Lees]

Re: Pre-war welded aileron hinge fittings

Good advice. Considering that even with a good fixture critical alignments can be lost. Always better to drill and final ream the steel AFTER all welding and stress relief.

Ha

Better to leave the steel "as welded & heat treated" and then press in the bronze bushings and then ream them to size. I'd hate to see bushings rotating in the welded fittings because of oversize reaming of the steel weldments.

Rob

[Guest]

Re: Pre-war welded aileron hinge fittings

My experience has been that the reamer (shell reamer) lasts about 30 seconds when I try to ream holes that had weld bead on the inside (from welds that were on the outside).

It was not a carbide reamer just hi-speed steel.

Dave

[Hank Jarrett]

Re: Pre-war welded aileron hinge fittings

Sounds like we are going to have to play with the first few to get the process right. I understand that the last process is the reaming of the bushing. The bushing is pressed into the steel after all is welded but is it required to ream the steel the bushing goes in to or is drilling acceptable? How critical is the interference between the bushing and steel? Anyone actually know?

Hank

[Guest]

Re: Pre-war welded aileron hinge fittings

There are recommended values of interference. Machinery handbook or some online site will give ranges.

The sellers of the bushings will tell you a range too.

Imagine for a moment that the piece that is supposed to hold the bushing was for example 3/8" O.D. and took a 5/16" o.d. bushing requiring an approx. 5/16" i.d.

If I was doing it and did not have a carbide reamer (I bet most of you do not) I would use a thick walled 3/8" tube with something like a 3/16" i.d.

After welding drill the tube to the final size (I bet most of you have a 5/16" drill bit or can get one easily) or something close too it for reaming to final size.

The point is to use thick wall tubing and then drill a lot of material out from a smaller i.d. so you can use a drill bit and utilize a large portion of the sharpened edge of the drill bit.

This is preferred rather than trying to just clean out weld deposit and using only the corner of the edge and chipping/dulling it immediately.

I place many bushings in small holes that I made with merely a drill bit.

The reamer I mentioned earlier is 1.90" diameter and used to reamed a 2" tube with .062" wall, drill bit is not going to work for me there and I cannot start with thick walled 2" tube.

Hope this helps, Dave.

[Hank Jarrett]

Re: Pre-war welded aileron hinge fittings

Sounds a lot like how the machinists did it and the Navy Depot when I was there. The SMART engineers always asked the old hand machinists the right way to do this kind of thing. I always remembered them drilling first, then reaming.

Hank

[astjp2]

Re: Pre-war welded aileron hinge fittings

They would be admitting liability...that is why they don't.

I guess because there was never a catastrophic failure that brought about an AD. Looking forward, a sensible TC holder would offer new steel ones as a suitable replacement at next re-cover. The TC holder would make money; sensible owners would buy them; the aircraft would be safer, no AD required.

It's good that sensible owners are offering a sensible route for replacement.

Am I missing something?

Rob

[Garry Crookham]

Re: Pre-war welded aileron hinge fittings

I'm in for a set for each wing.

[Jim Herpst]

Re: Pre-war welded aileron hinge fittings

Where does this stand? I am in.

[Hank Jarrett]

Re: Pre-war welded aileron hinge fittings

We don't have a lot of people who want them, which will drive teh cost up a bit (got to amortize the cost of the tooling over how many we sell). How many of which do you need? We will probably start with the inner and outer hinge fittings since there are a lot more of them and they are simpler to tool up for. That should help drop the cost of the bell-crank fitting.

Hank

[kona4breakfast]

Re: Pre-war welded aileron hinge fittings

I'd be interested in 2 sets of inner/outers. Don't need the middle fitting. Mine are just in bad shape where they attach to the cove.

[Ron Coleman]

Re: Pre-war welded aileron hinge fittings

Second try...I would like to have a full set,
Thanks
RonC

[Ron Coleman]

Re: Pre-war welded aileron hinge fittings

Second try...I would like to have a full set,
Thanks
RonC

[Jim Herpst]

Re: Pre-war welded aileron hinge fittings

We don't have a lot of people who want them, which will drive teh cost up a bit (got to amortize the cost of the tooling over how many we sell). How many of which do you need? We will probably start with the inner and outer hinge fittings since there are a lot more of them and they are simpler to tool up for. That should help drop the cost of the bell-crank fitting.

Hank

Hank I am in for a full set- both wings. Lets get a cost on the full set.

[Hank Jarrett]

Re: Pre-war welded aileron hinge fittings

OK, as it stands right now I have the following;

Hank Jarrett 4 hinges L&R Hinge Crank
Jim Hanson 4 hinges L&R Hinge Crank
Tim Popp 4 hinges L&R Hinge Crank
Niri Tawä 4 hinges L&R Hinge Crank
Bernard Dunn 4 hinges L&R Hinge Crank 2 welded and two tacked (give me a call, not sure what that means)
Jake Ring 4 hinges L&R Hinge Crank
Mike Padisak 2 hinges one Hinge Crank, give me a call. Left or right?
Garry Crookham 4 hinges L&R Hinge Crank
Michael Koen ? hinges ? Hinge Crank How many of which do you want?
Jake Ring 4 hinges No Hinge Cranks
Ron Coleman 4 hinges L&R Hinge Crank
Jim Herpst 4 hinges L&R Hinge Crank

Please let me know if there are any errors or fill in the missing info. I will try and get the box here cleaned out soon but am in a slight family problem right now (father in for surgery). My email is h j a r r e t t at c o x dot n e t. PLEASE don't tell me any of you guys can't figure that one out!!!! ;-)

Hank

[Robert Lees]

Re: Pre-war welded aileron hinge fittings

I don't need any, but as an innocent bystander, what is a "hinge crank" ?