aileron stop bracket
 

Does anyone know the best way to position the aileron stop bracket? The plans show aprox. position and give reference to sect. 15 for min and max travel. There isn't any room to clamp the bracket for drilling.

Here is a shot of how my stop was positioned. Basically as Van's suggested. It should not be a problem to position it, clamp it, and drill. You may need to remove the aileron for drilling and riveting. Trial fitting parts many times is part of the building process, very often, to get good results.

Roberta

Make a locating fixutre
 

To locate the aileron stop, I first installed the aileron on the wing, and centered it as specified in the plans. Then I adjusted the aileron push rod to the neutral position using Van's fixture. Leaving the pushrod pinned in the neutral position, I removed the aileron.

Next I made a aileron stop locating fixture from a piece of flat bar that was the same dimensions as the inboard flange of the aileron hinge, including holes for the hinge bolt and the push rod bolt. Then I installed it as if it were the aileron hinge.

After measuring the angular position of this aileron stop locating fixture with the pushrod still in the neutral position, I unpinned the aileron bell crank and moved the aileron stop locating fixture to the maximum up position and clamped it there.

Then I located the aileron stop against the edge of the locating fixture (which is the same as the aileron hinge) and riveted it in place.

The process was easy and the results were very good.

Yeah, this was a bit of a puzzle. You can't clamp the aileron stop, at least I couldn't. I went low tech and used ordinary painters tape to hold the stop in place. I started by loosely taping at about the right spot, then I moved the aileron through the motion to the desired angles. Since the tape gives a little, I used the aileron to nudge the aileron into a reasonably precise spot, checking angles with the digital level.
I then retaped the stop more firmly, checked the swing again making sure it was still good without give or nudges, then pulled the aileron off and drilled. I ended up with 16.5/28 degree swings each side.

aileron stop
 

I used a piece of delrin rod as described on Mickey's RV 8 site - works great. I ordered the delrin from onlinemetals.com. You can order as little as a foot. Here is the link to Mickey's aileron stop. http://www.rv8.ch/article.php?story=...aileron%2Bstop

You could do away with all that fussing and apply Mickey Coggin's very clever and elegantly simple solution to the problem by using Delrin rod as aileron stops. This photo shows close-up detail of one wing temporarily using several area washers to achieve the correct travel. I experimented using different size washers as a "mock-up" tool to help determine the correct diameter Delrin to order. The area washers shown in the photo were replaced when a small length of Delrin rod arrived. The highly workable material was then cut to length and drilled to fit.

Maybe I'm just being dense this morning, but I don't see how this works...

Follow the link from above:
http://www.rv8.ch/article.php?story=...ron%2Bstop

You will see where thewashers/delrin hit the aileron bracket.

This can be even simpler: Lowes sells these in the misc hardware section. I can't remember the size I ended up buying. I bought several.

Pictures and description
 

I used Mickey's idea: http://websites.expercraft.com/PHVII...y&log_id=18921 for details.

Delrin Size for RV7?
 

I am in the process of rig'n the wings to fuse.
I have been playing with the Aileron adjustment relative to the control Stick being 90 (using digital level). After adjustment, I checked my Aileron Up/Down Travel limits per Vans spec's. I am right at the max limits for travel (32/17 Deg) without the the Aileron stops installed. I would like to use the delrin method and would appreciate if anyone could tell me what diamter to use? The larger the diamter, the less travel the Aileron will have.

Thanks Folks