Aileron Construction :: Ail_CW_Mold_1
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AileronRigging 4 Counterweights - 2 Counterweight Casting - 1 Note: The procedure recommended by the Lancair manuals to attach the weights furnished in the kit to the aileron was far less than easy or satisfactory. We decided to work a better solution by casting weights into a mold that fits the profile of the aileron and wing better. This picture shows the profile of the weight. We made a mold out of bondo using this plug. Two full-size weights were cast and a smaller, third one was cast using the remainder of the lead that we calculated would slightly over balance the aileron. The weights are attached, starting at the inboard end of the leading edge flange with a hysol/flox mix and clamped until cured. Three bolts were then installed through each weight and flange. The nuts are low profile lock nuts and were countersunk in the lead. Counterweight Casting - 2 Endcap Fabrication - 1 Endcap Fabrication - 2 Trim Servo - 1
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Counterweight Casting - 2
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Counterweight Casting - 2

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AileronRigging 4 Counterweights - 2 Counterweight Casting - 1 Note: The procedure recommended by the Lancair manuals to attach the weights furnished in the kit to the aileron was far less than easy or satisfactory. We decided to work a better solution by casting weights into a mold that fits the profile of the aileron and wing better. This picture shows the profile of the weight. We made a mold out of bondo using this plug. Two full-size weights were cast and a smaller, third one was cast using the remainder of the lead that we calculated would slightly over balance the aileron. The weights are attached, starting at the inboard end of the leading edge flange with a hysol/flox mix and clamped until cured. Three bolts were then installed through each weight and flange. The nuts are low profile lock nuts and were countersunk in the lead. Counterweight Casting - 2 Endcap Fabrication - 1 Endcap Fabrication - 2 Trim Servo - 1
First Photo (Accesskey 'F') Previous Photo (Accesskey 'P') 10 of 15 Next Photo (Accesskey 'N') Last Photo (Accesskey 'L')
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Gallery: Pix navigate UP Album: Lancair Super ES navigate UP Album: Aileron Construction navigate UP (accesskey 'U')
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