It has been a frustrating few days as when I'd finished the first tube of T-88 epoxy I found that the second tube had gone hard so I was unable to make any progress on the ribs. Today, I'm still waiting for fresh glue to arrive so I cleared the worktable and decided to make a start on the ailerons and flaps. I'd constructed the torque tubes back in August last year
http://tailwindbuild.blogspot.com/2008/08/8h-august-2008-flap-and-aileron.html so first job was to make the hinges which need to be in place on the torque tubes before the ribs are added. First I added a dummy aileron spar and dummy sections of skin to the rear of one of the ribs. This then gave the spacing and angles for the 0.071" thick 4130 steel plates that will bolt through the wing to secure the ailerons and flaps. The hinge itself is 1-3/8" diameter 0.058" thick 4130 tube which is a good fit around the 1-1/4" diameter torque rods. The 4 hinges for the right wing were constructed in a single
piece and then sawn up. The plates were both welded to the tubing and also brazed as it seems pretty important that they don't fail! A 3/16" hole was drilled through the top of the tubing to allow the joint to be oiled. The second picture shows the profile of the weld and the fillet of braze metal. Then, with the hinges installed, the torque tubes were clamped to the bench ensuring that they were exactly straight and level. Finally a jig was made to hold the ribs (3/8" tubing) at right angles to the torque tubes and aligned with the centre line.
It has been a frustrating few days as when I'd finished the first tube of T-88 epoxy I found that the second tube had gone hard so I was unable to make any progress on the ribs. Today, I'm still waiting for fresh glue to arrive so I cleared the worktable and decided to make a start on the ailerons and flaps. I'd constructed the torque tubes back in August last year http://tailwindbuild.blogspot.com/2008/08/8h-august-2008-flap-and-aileron.html so first job was to make the hinges which need to be in place on the torque tubes before the ribs are added. First I added a dummy aileron spar and dummy sections of skin to the rear of one of the ribs. This then gave the spacing and angles for the 0.071" thick 4130 steel plates that will bolt through the wing to secure the ailerons and flaps. The hinge itself is 1-3/8" diameter 0.058" thick 4130 tube which is a good fit around the 1-1/4" diameter torque rods. The 4 hinges for the right wing were constructed in a single 
piece and then sawn up. The plates were both welded to the tubing and also brazed as it seems pretty important that they don't fail! A 3/16" hole was drilled through the top of the tubing to allow the joint to be oiled. The second picture shows the profile of the weld and the fillet of braze metal. Then, with the hinges installed, the torque tubes were clamped to the bench ensuring that they were exactly straight and level. Finally a jig was made to hold the ribs (3/8" tubing) at right angles to the torque tubes and aligned with the centre line.
