Wirelocking the aileron hinge pins.

[Shay King]

Just wondering if it’s ok to drill a small hole in the aileron hinge block to anchor the locking wire that secures the aileron hinge pin in place. Or, are builders screwing on a metal tab for this purpose?
Also, I’m ready to cut my first aileron free. The nose ribs are in place. Still have to decide how much of a gap to leave. Any last minute advice welcome.

[Kamcoman77]

On page 8 of the XL plans, Leonard suggests a 1/4" gap for aileron clearance. He also states a hole should be drilled in the aileron hinge block to secure the hinge bolt safety wire.

[Shay King]

Thanks Keith,I should have read through again… Doh!

[Kamcoman77]

I used the Iron Designs K-block aileron cove system and a fiberglass cove cover. I have about a 3/16" gap between my cove cover and aileron nose ply. I hope it's enough!

[DA Miller]

A little too much is a lot better than a little too small  

[Tom H]

About wirelocking the aileron hinge bolt - - - I have inspection holes at the inner aileron hinge pin location on DE Stubby. During an annual condition inspection a couple years ago, I noticed that the pin was slightly rotating when the aileron was moved. As I remember from plans, the hinge pin was a long 1/4" bolt with threads cut off and head drilled for safety wire to attach to the support block. I was concerned about movement possibly breaking the safety wire and allowing the bolt to work itself free. So, I modified the bolt by welding a zig-zag steel strip to the bolt head, and attached the other end of the strip to the rib with a screw/elastic nut. The flat screw head is counter-sunk into the outer surface of the rib, making it flush. Thus, the hinge bolt is held so it can not rotate or retract. Hopefully, this picture makes this all clear.

[Shay King]

Certainly looks secure.