kkshazzam

I have a 1/4 scale Texan that needs to have the aileron control horns installed. The ailerons are foam core, sheeted in balsa, covered in coverite and then finished in monokote.
My first choice would be to not drill a 1/2" hole and put a dowel rod in the already finished aileron.
Are there any other control horns that would work well here?

phughes

You did not mention if there is a reinforcing element involved (ply plate that you could screw to). I have to ask . . .did you really place monokote over Super Coverite?

CAP232CM

My Feedback: (8)

Well if there is no hardwood block or plate inside the aileron I'm not sure anything would hold up because your going to crush it when you tighten down the control horn.

Sounds like your going to have to drill that hole and put in a hardwood dowl.

kkshazzam

Sure did! I must admit that when I first heard the idea I thought it was crazy but if you think about it, it is a pretty good idea.
One of the long time club members has been doing it forever. It is a great source of strength and much easier and lighter than glassing.
The nylon reinforced material goes on easy and has plenty of glue for attaching to the balsa sheeting.
I don't like the finish of coverite so then you apply the monokote. It gives you a very strong, light weight, smooth gloss finish.
Try it before you knock it!

The bad news is that I may have to drill my ailerons and install a wood dowel for the horn.

kkshazzam

It would pretty easy to cut away the monokote/coverite and glue a plywood plate down.
Would that be sufficient?

R. C. Day

My Feedback: (7)

Kkshazzam,
The cleanest method would be to cut out the horns form plywood and epoxy them into a slot in the ailerons. Flight loads may not allow, however.

R. C.

kkshazzam

I like that idea. What thickness of plywood is acceptable for making control horns? Do you do anything special to make sure that the ball doesn't tear out of the end of the horn?

Another thought is to drill maybe a 1/4 inch hole in the aileron and epoxy the dowel rod in. The control horn wouldn't actually bolt to the dowel but it would stop me from crushing the aileron when I tighten the horn.

Thoughts?

phughes

You are the first person that I have heard of using the coverite, and monokote . . works for great!

Why are you opposed to using a piece of brass tubing 1/2 id and cutting a hole, placing a drilled and tapped dowel in the hole with epoxy? If done right it is quick, strong, and not very noticable if you use a finish washer under the head of the screw that becomes your control horn. I use the Nelson arms (formerly rocket city) and the installation is clean, strong and simple.

F1race79

My Feedback: (6)

The weave doesn't show through????

kkshazzam

Nope! The covering looks great and the coverite adds a significant strength.
Here are some pictures of the wing with the coverite and monokote.

www.raymondstacy.com/texan/index.htm

I drilled the hole in the ailerons using a piece of brass tubing. I cant believe how well that works!
The dowel rod is glued in and waiting for the epoxy to dry.

kkshazzam

Did Nelson take over all of the Rocket City stuff?
Is there a web site?

phughes

Yes, Nelson is selling (I do not know if they manufacture them, but what does that matter . . . right). The link is as follows

http://www.nelsonhobby.com/

. . .you will love their "stuff" if you have never used other items like this it will change the way you set up all of your projects.

kkshazzam

Thanks. Ill check it out.