Aileron skin problem

rebel · Post by **rebel** » Sat Feb 18, 2012 9:23 am

I was stoked yesterday when I got my first aileron all clecoed together and
it actually looks like an airplane part. Today was kind of a downer though.
When I bent over the rear edges of the leading edge skin between the ribs.
I used my homemade edge roller. The 1/4" edge I bent over is pretty wavy. It
didn't"t just roll over nicely like I was hoping. The actual edge that will
touch the fabric is pretty straight, and probably with the the fabric and
tape on there it will look fine, but I will have to look at that ugly
bent-over edge until then, and worse I dread having to butcher 3 more
ailerons like that. Is there a better way? The instructions say to use a
block of wood with a notch in it, so I can't imagine my roller is doing
worse than that. I was thinking about making a mini break out of wood, and
bending the skin removed from the aileron and clamped on the table. It
seems
like the problem is that the spar flange doesn't provide enough support for
bending the skin.
Please help.
Thanks.
Jesse Jenks

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steve whitenect · Post by **steve whitenect** » Sat Feb 18, 2012 9:23 am

Hi Jesse
Sounds like yr stretching the edge. If u use the roller, only use it
several times--- more will elongate the edge so it won't lay flat. Very
common with soft alum with a bit of over-working. Chafe tape and fabric will
hide alot.

Steve W. Rebel 637

From: rebel@dcsol.com
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Aileron skin problem
Date: Thu, 19 Aug 2004 20:25:29 -0800

I was stoked yesterday when I got my first aileron all clecoed together and
it actually looks like an airplane part. Today was kind of a downer though.
When I bent over the rear edges of the leading edge skin between the ribs.
I used my homemade edge roller. The 1/4" edge I bent over is pretty wavy.
It
didn't"t just roll over nicely like I was hoping. The actual edge that will
touch the fabric is pretty straight, and probably with the the fabric and
tape on there it will look fine, but I will have to look at that ugly
bent-over edge until then, and worse I dread having to butcher 3 more
ailerons like that. Is there a better way? The instructions say to use a
block of wood with a notch in it, so I can't imagine my roller is doing
worse than that. I was thinking about making a mini break out of wood, and
bending the skin removed from the aileron and clamped on the table. It
seems
like the problem is that the spar flange doesn't provide enough support for
bending the skin.
Please help.
Thanks.
Jesse Jenks

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Jesse Jenks · Post by **Jesse Jenks** » Sat Feb 18, 2012 9:23 am

Thanks Steve,
would I do better with the notched wood method? How do most people do this
step?
Jesse

From: "steve whitenect" <srwhitenect@hotmail.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: RE: Aileron skin problem
Date: Fri, 20 Aug 2004 16:20:08 +0000

Hi Jesse
Sounds like yr stretching the edge. If u use the roller, only use it
several times--- more will elongate the edge so it won't lay flat. Very
common with soft alum with a bit of over-working. Chafe tape and fabric
will
hide alot.

Steve W. Rebel 637

From: rebel@dcsol.com
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Aileron skin problem
Date: Thu, 19 Aug 2004 20:25:29 -0800

I was stoked yesterday when I got my first aileron all clecoed together
and
it actually looks like an airplane part. Today was kind of a downer
though.
When I bent over the rear edges of the leading edge skin between the
ribs.
I used my homemade edge roller. The 1/4" edge I bent over is pretty wavy.
It
didn't"t just roll over nicely like I was hoping. The actual edge that
will
touch the fabric is pretty straight, and probably with the the fabric and
tape on there it will look fine, but I will have to look at that ugly
bent-over edge until then, and worse I dread having to butcher 3 more
ailerons like that. Is there a better way? The instructions say to use a
block of wood with a notch in it, so I can't imagine my roller is doing
worse than that. I was thinking about making a mini break out of wood,
and
bending the skin removed from the aileron and clamped on the table. It
seems
like the problem is that the spar flange doesn't provide enough support
for
bending the skin.
Please help.
Thanks.
Jesse Jenks

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Robert and Olga · Post by **Robert and Olga** » Sat Feb 18, 2012 9:23 am

Jesse: When I built my Rebel and came to this step, I had two pieces of wood
screwed together about 1" shorter on each side then the rib spacing. Clamp
on the skin, and very gently flex down until you get the required amount of
bend. I had great success with nice straight bends and edges. Bob J Rebel
652.

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Jesse Jenks · Post by **Jesse Jenks** » Sat Feb 18, 2012 9:23 am

Thank you Bob,
I was thinking of something like that too. I wish I would have tried it. Oh
well, I will do it for the other 3.
Jesse

From: "Robert and Olga" <rjohnson18@cogeco.ca>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Aileron skin problem
Date: Fri, 20 Aug 2004 19:37:37 -0400

Jesse: When I built my Rebel and came to this step, I had two pieces of
wood
screwed together about 1" shorter on each side then the rib spacing. Clamp
on the skin, and very gently flex down until you get the required amount of
bend. I had great success with nice straight bends and edges. Bob J Rebel
652.

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steve whitenect · Post by **steve whitenect** » Sat Feb 18, 2012 9:26 am

Hi Jesse
Just use the roller but don't overwork it. Several complete passes shud do
it slightly increasing the angle on each pass.
Steve

From: "Jesse Jenks" <jessejenks@hotmail.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: RE: Aileron skin problem
Date: Fri, 20 Aug 2004 13:43:01 -0700

Thanks Steve,
would I do better with the notched wood method? How do most people do this
step?
Jesse

From: "steve whitenect" <srwhitenect@hotmail.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: RE: Aileron skin problem
Date: Fri, 20 Aug 2004 16:20:08 +0000

Hi Jesse
Sounds like yr stretching the edge. If u use the roller, only use it
several times--- more will elongate the edge so it won't lay flat. Very
common with soft alum with a bit of over-working. Chafe tape and fabric
will
hide alot.

Steve W. Rebel 637

From: rebel@dcsol.com
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Aileron skin problem
Date: Thu, 19 Aug 2004 20:25:29 -0800

I was stoked yesterday when I got my first aileron all clecoed together
and
it actually looks like an airplane part. Today was kind of a downer
though.
When I bent over the rear edges of the leading edge skin between the
ribs.
I used my homemade edge roller. The 1/4" edge I bent over is pretty
wavy.
It
didn't"t just roll over nicely like I was hoping. The actual edge that
will
touch the fabric is pretty straight, and probably with the the fabric
and
tape on there it will look fine, but I will have to look at that ugly
bent-over edge until then, and worse I dread having to butcher 3 more
ailerons like that. Is there a better way? The instructions say to use
a
block of wood with a notch in it, so I can't imagine my roller is doing
worse than that. I was thinking about making a mini break out of wood,
and
bending the skin removed from the aileron and clamped on the table. It
seems
like the problem is that the spar flange doesn't provide enough support
for
bending the skin.
Please help.
Thanks.
Jesse Jenks

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Jesse Jenks · Post by **Jesse Jenks** » Sat Feb 18, 2012 9:26 am

Steve,
I am going to try clamping between blocks first. I'm scared of the roller
now. I'll tell you how it goes.
Thanks
Jesse

From: "steve whitenect" <srwhitenect@hotmail.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: RE: Aileron skin problem
Date: Mon, 23 Aug 2004 16:48:11 +0000

Hi Jesse
Just use the roller but don't overwork it. Several complete passes shud do
it slightly increasing the angle on each pass.
Steve

From: "Jesse Jenks" <jessejenks@hotmail.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: RE: Aileron skin problem
Date: Fri, 20 Aug 2004 13:43:01 -0700

Thanks Steve,
would I do better with the notched wood method? How do most people do
this
step?
Jesse

From: "steve whitenect" <srwhitenect@hotmail.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: RE: Aileron skin problem
Date: Fri, 20 Aug 2004 16:20:08 +0000

Hi Jesse
Sounds like yr stretching the edge. If u use the roller, only use it
several times--- more will elongate the edge so it won't lay flat. Very
common with soft alum with a bit of over-working. Chafe tape and fabric
will
hide alot.

Steve W. Rebel 637

together
and though. ribs.
wavy.
that
will
and
use
a
doing
wood,
and
It
support
for _________________________________________________________________
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Jesse Jenks · Post by **Jesse Jenks** » Sat Feb 18, 2012 9:27 am

Thanks Bob,
I used this method on my second aileron and it worked great. I got a nice
straight bend line. I tried clamping the wood together with a bunch of Quick
Clamps, but it wasn't tight enough to get a crisp bend, so I screwed it
together which did hold it.
By the time I get to aileron #4 I should have it all figured out!
Jesse

From: "Robert and Olga" <rjohnson18@cogeco.ca>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Aileron skin problem
Date: Fri, 20 Aug 2004 19:37:37 -0400

Jesse: When I built my Rebel and came to this step, I had two pieces of
wood
screwed together about 1" shorter on each side then the rib spacing. Clamp
on the skin, and very gently flex down until you get the required amount of
bend. I had great success with nice straight bends and edges. Bob J Rebel
652.

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