aileron

[Ray]

Hey guys I'm in the middle of a restoration and have a left aileron
eaten up with cancer. Can anyone out there help me. 1946 BC12D
No one has any parts so I'm looking either at a replacement or parts to rebuild, my trailing edge and some of the ribs are OK so I'm open to any sugestions.

[mulwyk]

Re: aileron

Ray:

Good project.

By "cancer" I assume you mean that water got into the aileron and caused corrosion to some of the aluminum parts and rot in portions of the wood spar. If that's the case, you're looking at rebuilding the aileron. No big deal, just takes lotsa time.
I'd suggest you start by opening up the aileron, taking some photos and posting them here.

Aluminum corrosion often looks worse than it is and can be cleaned up with scotchbrite pads. AC 43.13 shows repair procedures for the aluminum parts, and you can always obtain used parts from the folks here on the forum. The wood spar material is available from Aircraft Spruce, you can make a new spar by just copying the old one.

You can also "improve" your aileron design when you rebuild it by using epoxy varnish and primers and installing nut plates behind those horrid hinge attach points.

Let's see some pictures.

[Ray]

Re: aileron

Yes that is exactly what I mean and a gentleman from New york is helping me. The corrision is so bad that the nose ribs flat part which holds the leading edge purchase is gone. Thank god some one was out there to help. Please advise on the upgrade you are takling about.

[mulwyk]

Re: aileron

Ray

Here's a couple pictures of my aileron rebuild.

The first shows the leading edge being installed, I used rope to gradually bend the leading edge around the nose ribs. The parts are primed with polyfiber's white epoxy primer, the spar is finished with epoxy varnish.

The second photo shows a nut plate behind the hinge fitting. The nut plate allows tightening the hinge bolts from the front side and it is less likely to crush the spar.

[Ray36048]

Re: aileron

Bob has some good pictures. You need a stiff fixture to hold the spar straight untill the leading edge is attached.