Aileron Gussets

[Chewie]

Do the diagonal (flanged) edges the corner and hinge gussets on the Patrol ailerons have to meet at a point as shown in the plans? I accidentally made the small ends of my corner gussets too long, so now there is an offset where they meet. Does this matter? Will fabric catch or something? That diagonal line in the photo is where the corner gusset flange would be if they were to meet at a point.

Just seeing if I should remake the corners, as they have already been flanged. The Patrol has 16 gussets on the two ailerons, so I've been chipping away at these for a while!

Thanks

[nichzimmerman]

I would ask Bob if I were you. Those appear to be meant to prevent bending of the end rib with fabric shrinkage and flight loads. Removing the flange from some of that means you could have .025" aluminum in compression without a corner to stiffen it.

I hear you on the number of gussets. Once I finished the ribs and had the nose skins, attach angles, and spars bent I thought I only had to assemble the ailerons and flaps, but once you get started you realize there are still quite a few more parts to fabricate! The joys of scratch building...

Nic

[geraldmorrissey]

As I see it, the flanges of both gussets that are bent normal to the top (or bottom) surface of the gussets should indeed come together at the intersection point, as shown on the drawing, and should be conmon to one another as they extend down (or up). I planned to add a small strip of aluminum to the inside surfaces where the flanges come together with one -3 rivet through each flange and the strip to tie the flanges together. Without that I see vibration on that unsupported intersection possibly doing damage to the fabric. Might be overkill but a small weight penalty while adding some stjffness to the structure. I would remake your corner gussets.
Gerry
Patrol #30

[Chewie]

There's a pile of random .020 ready for action at the end of my bench. I think the answer has presented itself. Thanks gents!