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I am currently rigging the ailerons prior to wing closing. After sanding
the lower wing skins for clearance, I find that the left aileron hinge
binds when moving in the up direction. It travels freely from full down
deflection to about the neutral position, then I start feeling
resistance. If I keep going, I hear and feel a "click", then it moves
through the rest of the travel with only a little squeaking. I have not
lubed the hinge yet, since I don't want to contaminate the composites at
this point.

With the aileron and hinge off the wing, everything moves freely, unless
I pull really hard on the hinge while moving it. In that case, I feel a
very slight binding, but nothing like when the aileron is installed on
the wing. Additionally, the hinge seems to be making a small amount of
aluminum dust when it is worked back and forth while mounted on the
wing.

Visual inspection reveals no obvious spot where something is rubbing or
sticking out to catch on the upper wing skin. I have not taken out the
hinge pin yet to examine the individual hinge halves.

Has anyone else experienced this problem? What steps should I take to
diagnose this? My only theory right now is that screws which go through
the upper wing skin are somehow exerting a large force on the hinge due
to some sort of alignment problem.

Thanks for your help,
Adam Molny
Legacy kit #151

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