Aileron counter balance tube

[Jflyer]

Interesting. I'll try some of the tough ones to see if can do it, but have plenty of help.

[markphillips1228]

Well this weekend I filled my counter balance tube, It was easier than I thought. I had a couple small sections of steel tube that fit nicely into my counter balance tube. I had a bucket of damp sand and poked the tubes into the sand to make a hole. to my dismay the sand collapsed into the hole. There went my idea. Never fear I had an idea. I wrapped a little masking tape around the tube, First layer sticky side out second layer sticky side in so I could slide it off the tube. I poked the tube into the sand then inserted the tape cylinder to keep it from collapsing. It worked I poured the molten lead into the form and it only singed the tape. I let it cool off and then had several lead plugs that slid inside my counter balance tube. Each plug was about 4-5 oz. I weighed my counterbalance tube then added the correct # of plugs to weigh about 5.5 lbs. each. Now I just need to put some epoxy into the tube to secure the plugs. There is a little bit of room left on each end of the tube to add some more weight if need be later. btw a coffee can and normal camp stove worked great. Be sure to wear gloves and eye protection.

[jaredyates]

And a respirator!

[David Weber]

I will let you know. I am going to have to do all the rivieting myself also

[Erbman]

I used a totally different approach. I used lead wool and hammered it into a solid mass inside the tube with a steel rod. No melting, no vapors, and the same end result. Don't hammer too hard or you'll make the tube swell!

In the end I figured it would have been easier to make the holes a little bit bigger and use a thick wall steel tube. I could get the same weight and there were no hazardous substances.

Lead wool is available from McMaster-Carr. Looks like steel wool but is lead.

[bestbearhawk1231]

Thanks for the tip Russ, I will look into that. I had also noticed that Rotometals had 5/8" lead rods 1' long that I was looking at epoxying in and expanding to size with a steel rod. I don't know if I could even buy shotshell shot for the price they are asking for the lead rods.

[Bradrock]

The lead wool option seems a lot simpler than the hassle of melting lead. Is there any reason not to use this method?

[markphillips1228]

Things still going well with aileron construction. Got one done and the other almost done. Counter balance still looking good.