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Old Dec 07, 2005, 03:31 PM
Dances With The Wind
Brian Courtice's Avatar
United States, FL, Punta Gorda
Joined May 2002
6,512 Posts
Kevlar gap seal for center hinged ailerons.

I decided to try a new idea out on my Mini SR. I really hate leaving an unsealed gap between the wing and ailerons when using CA hinges to center hinge the ailerons.

Here is the solution I tried:
After the torque rods and CA hinges were installed as usual, I sprayed a strip of kevlar with a fairly heavy coat of 3M77, and applied the kevlar to the hinge area while the 3M was still wet.

Next I wetted out the kevlar with 5 min epoxy. I should have used a thinner, slower setting resin. As you can see the thick epoxy resulted in a pretty rough surface. I could have a much neater job that would have required less filler.

After the epoxy cured I applied some bondo to even out the surface. At this point I'm close, but I'll still need some spot filler and lots of primer to even everything out.

It works! The result is an airtight seal that can be painted, and a super strong hinge. There is no way this aileron will ever get pulled off in a hard landing.
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Old Dec 07, 2005, 03:58 PM
It could happen...
InTheLift's Avatar
Torrance, California
Joined Jan 2004
7,537 Posts
Brian, looks like a great idea. I'll have to try that on a future build.
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Old Dec 07, 2005, 04:32 PM
Go get them Meg!
lrsudog's Avatar
Cabin 21...
Joined Jan 2001
2,118 Posts
Did the kevlar get "Fuzzy" when you sanded through the epoxy?
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Old Dec 07, 2005, 04:43 PM
Vitruvian JART
Reed's Avatar
San Francisco
Joined Mar 2003
5,019 Posts
Nice, Brian. That takes the old tape idea to another level.
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Old Dec 07, 2005, 04:46 PM
Crikey never leave beer behind
steve wenban's Avatar
Mt Annan Sydney Australia
Joined Dec 2003
23,138 Posts
Ive actually used solartex and resin wiped it worked extrememly well also
but Kevlar would be definetly stronger .
SteveW
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Old Dec 07, 2005, 04:53 PM
Dances With The Wind
Brian Courtice's Avatar
United States, FL, Punta Gorda
Joined May 2002
6,512 Posts
You do have to be carefull not to sand into the kevlar and fuzz it up. At the first sign of fuzz, stop sanding!

I've used clear tape over the paint like Reed does, but you can still see the gap and the hinges. I wanted something similar to the look you get when you cover a wing in Solartex or Ultracoat, with the fabric ironed down into the hinge gap.

Hmm. Solartex would be easier to cut and apply, and it is also paintable. That would have been easier, and it would have done the same job. The kevlar is stronger but you don't really need the strength if your hinge job was good to start with.
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Old Dec 07, 2005, 06:12 PM
Vitruvian JART
Reed's Avatar
San Francisco
Joined Mar 2003
5,019 Posts
I like Steve's solartex idea, too. I think I'll try that on my next build.
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Old Dec 07, 2005, 06:55 PM
Detail Freak
target's Avatar
Harbor City, CA
Joined Oct 2003
21,407 Posts
Quote:
Originally Posted by Reed
I like Steve's solartex idea, too. I think I'll try that on my next build.

I'v done that on my F-80. Works pretty good, but painting make the hinge action fairly stiff, be careful.

T
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Old Dec 07, 2005, 07:05 PM
Crikey never leave beer behind
steve wenban's Avatar
Mt Annan Sydney Australia
Joined Dec 2003
23,138 Posts
Clarification: I resin wipe the upper and lower surface not actually in the hinge line as for painting I use pin striping tape in the hinge line so it doesnt get clogged as Target said it would stiffen the throws up .But then again after the paint had dried,
and you manually move the sufaces up and down a few times the paint would yeild surely . Mind you thats only a guess as I said I dont paint the hine line
SteveW
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Old Dec 07, 2005, 11:59 PM
Registered User
bluffman's Avatar
United States, CA, Los Angeles
Joined Sep 2003
2,932 Posts
that look likes one tough wing brian great job Ian
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Old Dec 08, 2005, 12:57 AM
PNF
infopimp's Avatar
Los Gatos, CA
Joined May 2005
4,422 Posts
Seriously: those wings are SICK. That thing is going to haul a*5.
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