Aileron 2

Next comes time to c-sink the pipe.  You will want to clamp it down well, as it tends to want to move. 

To dimple the leading edge, you must use the punch from your c-frame with the pipe already clecoed in place.  It tends to make extremely small indentations on each side, but it should be okay.

Nose rib gets blind riveted to the pipe.  Bend the tab down to allow room for the riveter, then bend it back in place.

It is quite a trick to rivet the top skin to the spar.  I looked at a lot of different websites, and this seemed to be the best method.  You can do this with just one person (assuming your arms are long).  I picked up some handy 24" bar clamps from harbor freight to clamp the assembly down.

Once the top spar is riveted, you will fit and rivet the main ribs to the top skin and spar.  Prior to doing this, ensure that the leading edge skin is in the right position (on top of the trailing edge) on the bottom.  I mistakenly did not, and I had to drill out the main rib/bottom skin rivet to be able to pull the skin in the right order.  Also, you want to be sure you set both main rib/spar rivets, as you will not be able to access it with the brackets installed.

Next comes time to attach the brackets.  You can not fit a socket over the outboard bracket, so I went ahead and used the needle-nose vice grips with a torque wrench/crowfoot adapter.

Then, you lay the aileron flat on the table and cleco the bottom side in place.  It appears there is around 0.1" twist, so I am investigating ways to straighten it.

The instructions say to flip it over, weigh it down, then pop-rivet the bottom side. I basically did just that, but I used a LOT of weight. I cut a nice, flat board to the width of the aileron and loaded it down with four 25 lb bags of lead shot (distributed across board). That obviously kept the aileron flat on the table, while I proceeded to finish riveting the bottom edge. When I was finished, the edge came out perfectly straight...a maximum of 0.04" twist.

It's a lot of blind rivets to set, but ultimately you end up with a nice finished aileron.

Same procedure for the other aileron...no additional pictures.