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So....after all the work (a few years back) to split the ailerons, I have decided to make them 1-piece again. Primarily because I hope to enter this in some scale competitions and split ailerons would be a big deduction since they didn't exist on the full scale.
When I split them I used 1/8" CF/balsa/CF laminate for the end plates. I drilled and located 2 CF pins to tie them together. In addition to the hinge pin they are solidly located and act as one. Drilled additional holes in the end plates to allow the Hysol to squeeze in and further tie things together.
I will need to glue them and install on the wing while the Hysol cures so they remain in perfect alignment. Plan on applying some vaseline around the hinge pin holes....hopefully that will keep any epoxy from bonding to the hinge pin.....I HOPE!!!!
After all that work you are putting them back together. I have one plane with split ailerons and really like it. Why would you not put the pins in and a little shoogoo between the two and then cover it with covering no body would know and you can then always split them again.
Don't get me wrong....I had splits on my Raven and really liked them. But this plane is destined to be a scaled out Extra 330SC and will be entered in some high-end scale contests. It will get a custom paint job once I finish up the ailerons and a couple other scale touches planned.
So...ailerons back to the way they were....solid 1-piece
Got some more work done before all the family arrives and we stuff ourselves!
Ailerons joined with Hysol. Then just basic body work to blend everything so the joints disappear (hopefully). I tried some new (to me) Bondo Pro 2-part spot putty. Really works nicely although sets up very quickly. They advertise zero shrinkage, which is an issue for the older single stage stuff.
Although they look like hell until the get shot with primer, they are as smooth as a baby's butt....cannot feel or see the seam in low angle lighting. Of course when I get some primer on there will probably be a touch more sanding filler needed.
I think putting these things back together was as much, if not more work than splitting them!!!
I haven't tried either the Dolphin Glaze or the Stits.
Yes I do plan to fly with spades, although it will be maidened and setup 1st without them. Then attach the spade arms without the triangular plates and fly it. Lastly would be adding the plates.
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