Falconar F11A AILERONS

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Jan 20, 2006
The plans have arrived!  My first task was to redraw the Falconar F11A Plans in CAD.  This allowed me to study each part individually and to understand it's assembly.

Mar 30, 2006 
The wood is in!  I've started to build the first part of this giant jigsaw puzzle.  The Falconar F11A builder's manual recommends building the aileron first as it is fairly simple and will allow the builder to learn some of the techniques that will be needed throughout the construction project.  The wood was purchased from:

Western Aircraft Supply
Marc Septav
P.O. Box 79
Slocan, BC
V0G 2C0
(250) 355-0003
Fax: (250) 355-0004
Email: aircraft@telus.net

One word can both describe the service, and the product.  GREAT!!!!

April 8, 2006

I have about 4 hours invested.  Shown below are the finished parts.  The 4 stick figures are test pieces.

I am using a two part epoxy (G1 from Industrial Formulators).  The epoxy is great.  There is little or no smell, its easy to mix as it is a 1:1 ratio, and when wet, washes off with soap and water.

A basic rule of thumb, regardless of the adhesive used, is that the bond must be stronger than the wood. When the test pieces are crushed in a vice, and the epoxy mix was good, the result is as seen above.  I make two test samples from each glue batch, one is tested after 48 hours cure time, and one is kept on file for the Transport Canada Inspector.  The thought of a first true test of the glue bond effectiveness on an aircraft entirely held together with glue being coincident with the first flight does not appeal to me.  Keeping samples for the TC inspector will hopefully build some confidence in my construction methods. Additionally, the remaining test samples will eventually be stored in the aircraft.  I will be able to test the continued strength of the bonds over time as they are subjected to the same environment as the aircraft.  If/When the samples start to fail, it is time to retire the aircraft.  The added 1 or 2lbs to the aircraft is worth a ton of peace of mind.  

15 April. 2006

Another 7.5 hours invested (11.5 total).  Progress is good.  Having all the wood sized by Western (width and depth) leaving me only to cut to length is a tremendous time savings.



Below is the type of jig used to assemble the pieces.  I taped full sized drawings to a perfectly flat surface, covered the entire jig with clear plastic and then drove small nails around the perimeter of the drawings.  The nail heads were then cut off.  KIS. (Keep It Simple)  This technique allows me to build several parts at the same time.

After the aileron rib parts were fitted, the epoxy was mixed and the pieces assembled and clamped.  The last step was to make the sample pieces. 

You may have noticed small holes in the surfaces of some parts.  Along with he clamps, I use dozens of small nails to maintain pressure. (To show a better picture, many of the clamps were temporarily removed for this picture)  The nails are removed after the adhesive has cured and the holes are later filled with epoxy.  As can be seen, the aileron spar has been started (top of picture).

17 April, 2006

Another 3.5 hours invested (14 hours total)

Assembling the Aileron was a challenge especially aligning all the ribs to be perfectly centered.  I used a tip in the Falconar F11A builder's manual. A tight wire was strung between the 2x4s that can be seen in the picture above. This wire was centered over the spar and positioned at the required height.  The required distance between ribs was marked on the spar and on the wire.  

First, I dry fit the untrimmed ribs to the spar.  Using a straight edge, I marked the approximate angles on the parts.  I rough sanded the ribs under my measurements and reinstalled on the spar using clear tape.  Once all the ribs were rough fitted, I started over, making 3 or 4 passes of fitting, measuring, and sanding to ensure that the final product is exact. Each pass, the fit got tighter and cleaner until the final result as seen below .  Once everything was as perfect as I could make it, the epoxy was mixed and everything was assembled.  Lots of clamps, tape, and tacks held everything in place while the epoxy cured.  As can be seen in the picture above, my workshop is very small so all the smaller parts are being built first.  When the time comes to assemble all the parts, I will rent a larger workshop or hanger. 

April 21, 2006

Another 5 hours invested (21 hours total)

The Second Aileron is completed. (as far as I want to complete it at this time)  Items left to do:

Trailing edges
Gussets
Hinge attachment Areas

The trailing edges have not been trimmed to size as the cuts are difficult and I do not have the right tools (at this time) to guarantee a perfect job.   I am holding off the installation of the hinge attachment areas until the wing trailing edge is completed to assure a good fit between the two.  Without the trailing edges or hinge attachment areas installed, the gussets cannot be fitted. 

June 19, 2006

1hr - 61hrs total

With the new table saw, I was able to make a jig to trim the trailing edge.  The part shown in the picture above is the trailing edge.   Now I can begin final assembly of the ailerons.

July 1, 2006

4rs - 67hrs total.

After lots of sanding with my home-made sanding board, the ailerons are coming together nicely.  The sanding is required to ensure a flush fit for the gussets.

Oct 28th, 2006
6hrs - 368hrs Total

The hinges are started.