Warbird Information Exchange

Patrick, I'm using Klean-Strip Aircraft Paint Remover from my local auto paint store. Seem to work great. Blue and red can.

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"There are old pilots and bold pilots but few old, bold pilots."

Outboard aileron hinges were removed when the wings were chopped just outboard of the trim tab on the left aileron. Obviously, all need to be remade. The assembly is made up of the hinge, mount plates (3), and a cover plate that has an egg shaped deep drawn form. Here is progress on the hinges.

Blanked


Thought drilling and reaming at this stage would be beneficial.


The print calls for the hinges to be made from a CVC vendor provided extrusion, yeah well Next best thing.


Will finish the second hinge then go to final shape.

_________________
"There are old pilots and bold pilots but few old, bold pilots."

Nearly finished. Have had lots of distractions the past couple days but getting closer.



Shaping

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"There are old pilots and bold pilots but few old, bold pilots."

This is starting to remind me of those old cooking shows from long ago, where they'd be stirring a bowl of goop before the commercial, and pulling a beautiful cake out of the oven after. My gosh, it looks so EASY.

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Cheers,
Kurt Maurer
League City, Texas

PIC, Ford 6600 pulling Rhino batwing up and down the runway

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"There are old pilots and bold pilots but few old, bold pilots."

Hey Scott,

Thanks again for taking the time to make these posts.

Is there any particular reason that you removed the unwanted metal in the middle of the hinge before you did the shaping? Does it make the final shaping easier or is it just your preferred way of doing it.

Thanks,

Mac

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WWII Naval Aviation Research - Pacific
https://www.ww2nar-pac.com/

Mac, I just thought it would be easier that way. I guess it could have been done either way but I find it easier to shape the 1/8" cross sections rather than shaping the 1" cross section.

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"There are old pilots and bold pilots but few old, bold pilots."

Thanks for the answer, Scott. I have no machining skills or experience, so I was just curious.

As usual, I'm just in awe of the finished product that comes from the solid block of aluminum after you work your magic.

Mac

_________________
WWII Naval Aviation Research - Pacific
https://www.ww2nar-pac.com/

So, the hinges I finished are mounted in the aileron with three 1/4" flat head bolts each. Can't countersink the hinge base so these little countersunk washers are used. They are made from 2024-T3 .156" thick and machined with a radius on each lower edge to match the radius on the inside of the hinges. The blank was machined from 1/4" x 1". The width is .5893" plus .000" minus .020"???, countersunk to a diameter of .495" with no call out for the actual 1/4" hole diameter which was actually determined by the depth of the countersink.

Blanking


Center drilling and counter sinking. The original washer is on the vise.


After I radius the lower edges to fit the hinge, I can cut to length from the strip

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"There are old pilots and bold pilots but few old, bold pilots."

These require a 1/8" radius in order to lay in the root of the hinge without interference with the 3/16" radius in the hinge. Used the router to cut the radius. Had to make a fence since the strip was thinner than the height required to meet the bearing on the cutter.





Cut to length and finished, top side. Original piece far right


Lower side


As they fit in the hinge channel

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"There are old pilots and bold pilots but few old, bold pilots."

I feel dumb asking this, but how'd you make yer cuts? (I'd've used the band saw and squared up/prettied up on the sander.)

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Cheers,
Kurt Maurer
League City, Texas

PIC, Ford 6600 pulling Rhino batwing up and down the runway

Hacksaw and disc sander. High tech.

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"There are old pilots and bold pilots but few old, bold pilots."

I'm thinking this is getting a bit tedious for all you guys but this is day to day stuff for me. Sorry and it is what I face with my portion of this project. I love it but could be boring to most.

So, now that the hinge is done, we need to make the cut out reinforcing plate and other crush plates. Made the form block, test sample and LH cut out plate today. The ailerons curve up at the end so this plate has to have angled flanges to match the wooden ribs inside the aileron but still fit flush to the inner skin. Best part is that the drawings don't give you all the info needed. Yippee!

This is the RH center hinge but the concept is the same. Hinge channel, cutout plate and crush plates that sandwich the wood.


LH form block and sample test piece with the formed plate.


Will probably hold off on the heat treat of these until we can actually fit the wood, then heat treat and paint. I would hate to be off any on angles and stress the wood ribs if the plate is full hard and unyielding. Drags process out but then no concerns.

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"There are old pilots and bold pilots but few old, bold pilots."

Still very much enjoying this thread Scott.
If anyone is bored they can decide to not click on it.

Andy Scott

I'm generally pissed that you don't post more.