Aileron spar reinforments

[Robert Lees]

Re: Aileron spar reinforments

One of my Taylorcraft aileron spars was broken (see photo below).

I'm just replacing a Starduster aileron spar for a friend; I'll take some photos of that crushing.

[TimHicks]

Re: Aileron spar reinforments

Do we know what the correct torque is on these AN3 bolts/nuts to prevent damage?

[Guest]

Re: Aileron spar reinforments

I doubt it, torque on bolts thru wood is problematic- check out ac43.13 on that it has some good advice.

[Guest]

Re: Aileron spar reinforments

I looked at the pictures on this thread a few days ago and was perplexed so I went down to my other garage where I had an aileron sitting around with no fabric.

The spar is double thick at the point in the middle where the hinge and bracket for the control ball are.

That makes sense to me because the leading edge structure is absent there and it "strength" must be provided by something else. I believe that the double thick spar and the aluminum sheets on the top and bottom aft of the spar are there to provide that strength.

So here is why I was perplexed: why are some spars not double thick there? and why do some not have the aluminum sheets? Seems like someone in that past skipped a step or there was a design change at some point in time OR I am looking at the pictures wrong

Dave

[1938BF50]

Re: Aileron spar reinforments

This was the "good" aileron spar. I cant find the pix of the bad one. I rebuilt both to like new. I put nutplates behind the fittings so that I could mount them after covering and make a neat job of it.

[Guest]

Re: Aileron spar reinforments

Neat idea Mike!

[1938BF50]

Re: Aileron spar reinforments

I stole the idea from someone on this site....Rob Lees, I think. I put an AN-970 under the nutplates. I also precovered that area with fabric. They really came out nice.

[N96337]

Re: Aileron spar reinforments

Mine were double thick there too Dave, and also had the aluminum plate, top and bottom. I'd just removed it when I disassembled them and before I took the pics.

[swoeric]

Re: Aileron spar reinforments

thank you guys for the help.. I just got back from the airport where i finally got the nerve to cut the fabric. The spar look very new as does this entire wing inside compared to the other side. The hardware was also preserved nicely. The wood has shown no damage. As I wiggled (technical term) the bracket I realized that they had assembled it with several layers of thick paint between bracket and bolt. This paint has finally cracked and worn away leaving some play.

[Hank Jarrett]

Re: Aileron spar reinforments

Sounds like you are golden! When the paint starts wearing away the "looseness" will get worse fast! Kudos for finding it before it damaged the spar! You should be able to tighten the fasteners and be good. I would get used to reaching up and feeling the fitting on pre-flight (not because it will get bad again soon, but because I am paranoid). I also wiggle the push rods between the aileron and bell-crank on each pre-flight and lift the tail and play with the tail wheel spring for the same reason. I have seen too many of the cast aileron hinges cracked over the years, and MINE ARE WELDED STEEL! I still reach up and give them a little shake each time.
Sounds like a good time to start your rebuild list for the glove box. I keep a list of anything I would do a really good job on when it is time to recover. You know, little things that could be better but aren't a big thing now.
Item 1, don't forget to refinish the aileron spars under the hardware. I REALLY like the photos of the spar that had the hinge cove fabric covered prior to the rest of the aileron. GREAT idea. I'm stealing that one.
Hank