Hey Folks,
I was out last night working on my Tower Trainer 40 MKII hooking up the aileron's. Got one side hooked up fine. When I hooked up the other side, I first put some expoxy in the cutout area for the aileron torque rod to lay in and I also put some CA on the first 2 hinges closest to the torque rod (I had already installed the hinges with CA into the aileron). I went ahead and slipped the torque rod into the aileron about halfway while also trying to slip the the first two hinges into the wing, one by one.
Well, I didn't get the torque rod all the way into the groove before the CA started to setup in the first hinge. (I did manage to get the other hinges in). As a result, although I now have full upward deflection, I don't have full down on that aileron - only approximately halfway.
I saw the post below on how to use a heat gun to soften the epoxy and thought about going that route to pull the torque rod out and start over. Also, I guess I'd have to cut the hinges and re-slot the hinges to install new ones. I'm just wondering if I should do this at all or if the flight characteristics would justify it. I'm a little worried about the stress that might be on that torque rod as it is slightly angled going into the aileron. As far as reslotting the aileron and wing, I wouldn't have a clue as to attempting it. . .I don't have a slotting machine.
Thanks for any comments you might have.

I'm not sure what you mean by "full down". If you can deflect the aileron the amount specified in the instruction, then it's OK. Otherwise, I would cut it off and make it right.

What exactly is preventing the aileron from moving? If it is the hinges, then cut off the two bad ones and insert new ones along side.

When using Ca hinges, you NEVER apply the glue until everything is in place. Then add about 3 drops on each side. The Ca will work it's way into the joint. DO NOT put Ca on the hinge and expect to shove it into the slot.

It's easy to make new slots for Ca hinges, just use an exacto blade.

To

It looks like the reason that the aileron won't go all the way down is because I didn't fully seat the torque rod in the slot. I'm gonna use a heat gun to melt the epoxy, cut the hinges and try it again. Yea, I realize now not to put the CA on the hinge then slide it in the slot....major bonehead idea, but then again, I'm a newbie. Nothing like learning from your mistakes. Thanks.

F-16WpnsTech,
As mentioned above, the CA (thin only) is applied to the hinges after everything is in place and you have the control surface where you want it. Just to clarify, that means you do not glue the hinges to the control surface prior to installing it to the plane. Push a straight pin through the center of each hinge before inserting them so when everything is assembled the hinges will be centered between the control surface and the trailing edge. Be sure to pull the pins out before applying the CA. As far as using the heat gun to melt the epoxy on the torque rod, you're probably gonna melt off any covering in the area also.

try to use Epoxy for the hinges than CA as it not only holds stronger but you have more time to adjust all the hinges to the exact position.

To make hinges even more stronger...here is another tip...poke fine pins(the fine needles used for sewing) into the hinges....this is through the wood (either on the wing or the aileron)...this will really make sure the hinge will never come out if somehow the CA/epoxy dont work well.....it really doesn't cause any damage and it can't be seen as the tiny pins are in the wood.

You don't want to use epoxy on CA hinges. If you're using hinge points or plastic hinges, fine, but not on the thin Ca types.
Dennis-

Well, I cut the hinges and held a fine point soldering iron on the torque rod for a minute or so and it worked like a charm...had to turn the heat up pretty high though. Now for the second round.