Aluminum aileron coves

[Bud K]

How have you guys been bending the aluminum for the aileron coves?  I am building my wing using Scott's wing design but I am having problems forming the aluminum around the 'K' blocks.  I have the Harbor Freight shear/brake/roller but I can't form a radius tight enough to prevent it from flexing when installed. I am using the aluminum flashing from the hardware store.

[mike ketteman]

when I did mine I used some pvc drain pipe to push the cove down while the t88 dried

[Bud K]

Did the T-88 bond to the aluminum well?  How did you get the aluminum to be straight between the ribs?  Can you take a photo looking down the length of the aileron cove edge?

Thanks
Bud

[mike ketteman]

You still need the structure between the ribs per the plans,sand the Al at all contact points.

[Bud K]

Thanks

Bud

[scottiniowa]

when I did mine I used some pvc drain pipe to push the cove down while the t88 dried

• This is a very good suggestion by m4s0ez,  with a bit of searching you should be able to find the correct diam of tubing (maybe not just pvc-but anything) to hold this down, a few small brads don't hurt either. Just measure to insure your centered to the backing (rib) 
• Also-There are some bonding epoxies that really work well, for alum to wood- such as 3M-2216, but you need to find in small quantities as you won't need much. This just mentioned material will be stronger than either piece, so get it right the first time, there is NO redo for this.
• Also-The edge of the alum, top and bottom can be pre-creased in a brake to keep very strait.  Or firmly clamped between two blocks.  I would do this several times with a small piece of alum to ensure you get it just right on the larger-long piece.   Best of success to you.  Double check your bending radius to ensure your not getting it to tight. (i.e. cracking)