Aileron Hinge Bushing

[Rex Havis]

I am replacing the bushings in the aileron hinges and have encountered a problem. The tubing is to large for the bushings on three of the hinges. I've checked with the bushing suppliers in the area, they do not carry odd size bushings. I'm hopping that someone has found an answer for this problem.

[Hank Jarrett]

Re: Aileron Hinge Bushing

Are you looking at the aileron or the wing fittings the aileron hangs on? If it is the hinge fittings on the wing, and you have the cast ones, look them over VERY well. You may have cracked cast fittings that are making the holes too large.
If you have cast hinge fittings you should look them over really well anyway. They are VERY prone to corrosion and cracks.
If that isn't the problem, try posting a photo of the part you are talking about pointing to the bushing. Might be able to turn some custom bushing on the lathe.
Hank

[fearofpavement]

Re: Aileron Hinge Bushing

Cheap man's lathe: Chuck a section of the bushing material in a drill press, measure with a micrometer the existing o.d. Then run the drill press and hold a mill file gently against the bushing to "mill it down". Stop and check the dimensions frequently. Some trial and error and material attrition may result but it can be done this way. You will want a light press fit.

Notes: a new or very sharp file should be used. This is not the time to utilize that rusty one that came out of your grandpa's tool box. Also, you will want to work very close to the chuck as there will be too much flex farther out. Use a file with a handle so that in case it catches on something it won't perforate you. Run the press at a slow speed.

[Hank Jarrett]

Re: Aileron Hinge Bushing

MAKE SURE YOU HOLD THE FILE BACKWARDS!! You want the drill to be PULLING the file so that if it grabs it will throw the file AWAY from you!
Hank

And you thought those tools stuck in the wall were there for easy access.

[Robert Lees]

Re: Aileron Hinge Bushing

Rex,

Are you saying that your new bushings are sloppy in the casting? Or tight?

[Rex Havis]

Re: Aileron Hinge Bushing

Additional Information.

The aircraft is a 1940 model with welded up aileron hinges. the hinges attach to the rear wing spar. The new bushings have a 0.315 O.D. the tube that they should fit into has a 0.320 I.D.. I am using a digital caliper for these measurements. Thanks for the help, any additional thoughts will be appreciated

[Hank Jarrett]

Re: Aileron Hinge Bushing

I just went down and put my hands on a bellcrank hinge fitting and an inner and outer hinge. All welded assemblies in perfect NOS condition with no wear or corrosion. None of them have bushings and all of the hinge pin holes are 1/4" diameter.
Something is strange here unless they changed the design between 1940 and 1945. The 41 ones are exposed on the wing at the airport (ailerons are off right now) but I probably won't be able to get out there for a while.
This is strange.
Hank

[Ron Coleman]

Re: Aileron Hinge Bushing

I just replaced some bushings on my 46 BC12-D. The old bushings were stiff twist fit, but one end of the bushing was knurled. All of the bushings that I have to finish the job are also knurled on one end only. Keeps the bushilng from rotating and hogging out the fitting.
RonC

[Hank Jarrett]

Re: Aileron Hinge Bushing

I will try and take some pictures of the non-bushed ones I have. Can those with bushed ones post too so we can compare?
Hank

[3Dreaming]

Re: Aileron Hinge Bushing

Hank, I have never seen one yet without bushings, and that is several sets both pre and post war.

Rex, if they are loose at some point the pins were frozen in the bushing and the bushing were turning in the tube wearing the tube. You could try having them knurled at a machine shop and installing them with some Loctite bearing/sleeve retainer, or look for some P.005 bushing material.

[Rex Havis]

Re: Aileron Hinge Bushing

Thanks for the information, How does a machine shop knurl a bushing? Will they be able to knurl a bushing as thin as these bushings? Using a 0.005 bushing sheet to wrap around the bushing may be the best answer. I'll let you know if it works. Thanks to all Rex

[Ron Coleman]

Re: Aileron Hinge Bushing

You take a new bushing, put a tight fitting pin in the bushing and chuck it up in a lathe with the knurling area close to the chuck. Now use a knurling tool to stipple the bushing (not much).

RonC

[Pearson]

Re: Aileron Hinge Bushing

Since this is a welded up assembly, why not just remove it and replace the section of tubing the bushing goes into? You could bolt a plate to the part that bolts onto the spar and build a jig with a pin to go through the tubing, so that you maintain the correct distance between the two. Use a high speed cutoff wheel to remove the old tubing and weld a new one on.

[Hank Jarrett]

Re: Aileron Hinge Bushing

Sorry to take so long to post these but every time I turn around the #%&$(%&_)(@! camera cable is gone. I think the stupid thing has hidden legs.
This is what the "like new" fittings I have look like. No bushings, just a tube welded at the end. Anyone have photos of the configuration being discussed here?
Hank

[3Dreaming]

Re: Aileron Hinge Bushing

Hank, I think you need to take a closer look. I can see the bushing lines in the picture, at least on the outboard brackets.