Jabiru J450 Constructors Manual
Pre-Paint>Wings>Fit ailerons
Tuesday, April 6, 2010
184 of 343
Place the aileron hinges in those locations with the flat side of each hinge facing upwards and
the hinge pin aligned in the centre of the ~1mm gap between the aileron and the wing.
Do
not
place the hinge flat side down – if you do then the holes will not line up correctly
when you come to fit the hinge.
Use a 3/32” drill to make a pilot hole opposite the pin side of each rivet hole, check that the
hinge and hole positioning is correct and then carefully expand to 3/16” holes.
Test fit each hinge with 4 Clecoes and fit the hinge pin into place as shown above. Each hinge
pin is inserted from the inside towards the outside of each hinge. Mark the location of the end
of each hinge pin (circled at above right). Number each hinge and its location.
Check that the aileron to pre-mould strip gap is even along the full length then remove the
aileron and hinges.
Sand the flat side of each hinge and the locations where they will be fitted, then mix a small
batch of resin and coat each area. Add flock to the remaining resin and apply a 2mm layer of
flock to each hinge and flock into place using clean Clecoes in the outer holes as before.
Using a 120° countersink bit carefully countersink the 4 inner holes just enough so that a
countersunk rivet head will sit flush with the surface when fitted and rivet the 4 inner holes
with countersunk rivets. Now remove the Clecoes from the outside holes one at a time,
countersink each hole and fit a countersunk rivet until each hinge has 8 countersunk rivets.
Take care to keep flock away from the hinge pins during this step: clean the hinges while the
flock is still wet then leave both parts (wing and aileron) separate and leave overnight to cure,
then store the ailerons for later painting. Clean the Clecoes in acetone after use.
Next day use a rat tail file to make a slot into the wing at each hinge pin mark (example
circled at above right), fit the hinge pin and the hinge pin retainer, mark the retainer screw
hole and drill a 3/32” hole. Pop rivet a captive nut under each retaining screw hole using 2
3/32” countersunk rivets.