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 01Nov00, 1 hour - Laid up leading edge of tips.
03Nov00, 2 hours - Bonded seatpan flanges. Fiddled with the
trailing edge board for a better fit.
04Nov00, 4 hours - Began aileron lower panel fitting.  Cut
drilled & treated hinges. Fiddled with the trailing edge board
even more. Now it swings up & down well, and lands back where
it belongs.
05Nov00, 5 hours - Laid up aileron hinge reinforcements on aileron
and wing. Completed right split seatpan. Neal's method
worked out great. I'll finish the left pan once the fuel valve is
installed. Routed pitot lines & RF cables out of wing. Laid a 2-layer precure for aileron ribs.
07Nov00, .5 hours - Made aileron trim tab.
08Nov00, .5 hours - Alodyned hinges.
11Nov00, 5 hours - Fit & riveted left aileron. Fitting the
hinge to the wing required a jig. Since the holes can only be
drilled from below, the jig is clamped into place with the hinge in it's
final position, then the hinge is moved below the wing, referenced to
the jig, and the wing is drilled.
12Nov00, 6 hours - When attempting to fit right aileron hinges, I
found that the bottom edge fell about .020 below the wing, vs. the left which were
flush. Laid two extra layers of bid to raise them up. Fit
the left flap skins and trimmed the lower aileron skin trailing edge,
and the tip trailing edge. In fitting the left flap I found that
the trailing edge board as I've built it is not an ideal setup.
Since the flaps are recessed into the wing 1.1 inches relative to the
aileron, and the trailing edge of the wing is low with respect to a line
drawn tangent to the lower skin, the bottom surfaces of the aileron and
the flaps are not in exactly the same plane. The single
board cannot accommodate this, and I'm forced to adjust it to fit either
surface, but not both at once. A trailing edge only (perhaps a 2x2
angle as suggested by Byron Covey) would have been better.
14Nov00, 2 hours - Fit the right aileron hinges. An overlooked
wave in the bottom skin is distorting the right hinge, and I'll need to
pot it to ensure hinge alignment.
17Nov00, .5 hours - Potted the hinge.
18Nov00, 5 hours - Installed right aileron hinges. Fit the
right aileron top & bottom. I'm not happy with the hinge pin
retained angle I installed on the left side. Only 1/2" long,
it is held in with a single rivet. 2 rivets are called for given
the essential nature of the hinge pin. I removed the retainer, and
fabricated new retainers from fiberglass.
19Nov00, 7 hours - Fit fit aileron counterweights. Both
required reshaping of weights to clear J-rib and still achieve good fit
at the aileron. Must still cut left clearance slot.
20Nov00, 4 hours - Cut left slot. Fit and laid up ribs.
Installed a 1/4x1/4 foam block on bottom skin all along the trailing
edge, 1/2" in. This will be sanded to fit the top skin, and
will allow me to clamp the trailing edge when closing, without causing a
bow in the top skin.
 21Nov00, 6 hours - Worked on trailing edge bench to insure proper
aileron shape. The left top skin has a twist that must be take out
in closing. Installed counterweight nutplates. Trimmed
skins, sanded trailing edge foam block and ribs to fit. Had to
rework the left trailing edge foam blocks to allow for the trim
tab. Sanded skins thin at the trim tab to minimize any bow over
the tab. Rechecked up & down clearance with counterweights in
place. Prep-sanded & cleaned skins. Took a break, then
re-read manual up to closing, confirming all steps had been completed
successfully. Closed the ailerons!
22Nov00, 4 hours - Panic! When I release the clamps on the
ailerons this morning, the right rear corner of the left aileron sprang
up 1/16", the right rear of the right aileron 3/32".
After a bit of study, I realized that the bonding of the rear &
inboard of the aileron was not enough to take out the panel twist.
Hopefully the remaining layups will finish the job. Put Q-cell
radius in aileron. Re-installed flap hardware, trimmed ends of
right flap.
23Nov00, 4 hours - With the Q-cell, the aileron is holding it's
proper shape. Panic over. Completed layups on both ailerons.
 24Nov00, 2 hours - Potted aileron actuator brackets. Trimmed
trailing edge of right flap, fit top skin.
26Nov00, 7 hours - Fit flap shearweb, laid one side. Assembled
aileron brackets & push tubes. Drilled 7/8" hole in wing
shearweb to accommodate push tube. Could not hook up with
trailing edge jig in place, must wait till next time it is down.
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