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I started by taping a yard stick to the wing as a cutting guide. This proved very useful.<\/p>\n
I placed the inward side of the yard stick against the plastic reinforcer in the center of the wing. I cut my aileron from the 5″ mark, out to the 17″ mark. This makes for a foot-long aileron, which should be more than enough. I wonder now if I shouldn’t have cut the aileron all the way to the wing tip. I’ll report on that later.<\/p>\n The next step was to perform the cut, taking care to keep the blade straight along the edge of the yard stick, and also perpindicular to the wing surface. I cut the wing with it upside down, so I could work with the flat surface. Here’s the cut out:<\/p>\n Next I did the same thing to the other side of the wing. I labeled the two ailerons with an “L” and an “R” so I wouldn’t get them mixed up (I’ve been known to do that kind of thing).<\/p>\n Then I set each aileron on the desk and free-hand cut away the inside edge to give it room to pivot. I cut it at abou 45 degrees. It’s not a perfect cut, but it’s good enough.<\/p>\n Then I used some “park flyer hinge tape” sold at my local hobby shop (Some Dude’s Hobbies<\/a> are very helpful). It’s branded “3M Blenderm” and it is very<\/b> easy to work with. I set the aileron to the neutral position and laid down the tape. It’s very flexible, but very strong. Then I took a hair dryer and high heat, low fan, and slowly passed the heat over the tape for about 20 seconds. I then flipped the aileron upward to apply tape to the underside too. To do this, I pushed the aileron all the way up, leaving a nice flat surface for me to apply the tape to. Now that the tape is on, you can barely see it at all. Very nice:<\/p>\n Once the tape was in place, I used my fingers to give a gentle squeeze along the hinge line. This compressed the foam a bit, and gives the hinge a little more mobility.<\/p>\n Here’s what it looked like as I applied the bottom hinge tape:<\/p>\n And from the side:<\/p>\n Here’s a bird’s eye view so you can see how long the ailerons are, for your own measurements:<\/p>\n For reference, my ailerons are 12″ long, and about 1″ deep. Closer to the fuselage, they approach 1.25″ deep, and closer to the wing tips they approach 1″ deep.<\/p>\n The last step was to attach the control horn for the servo’s push rod to connect to. This is a DU-BRO brand push road (which I also purchased at Some Dude’s Hobbies<\/a>, where the staff is very helpful). It just had two ribbed plastic pins to attach to the foam. I “piloted” holes for them with a push pin (pun intended), and then coated them in my favorite epoxy (DevCon 5-Minute Epoxy), and shoved them in the holes. They aren’t perfectly straight, but I think they’ll work okay.<\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n