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2 1 8.4548.60 glass Twill 2/2 ±45º
3 1 8.3520.8 carbon ±45º
4 1 8.3520.8 carbon ±45º, 80 mm x 270 mm.
5 1 H 60 3 mm rigid foam
7 1 8.3520.8 carbon ±45º, 70 mm x 230 mm.
8 1 8.3520.8 carbon ±45º, 90 mm wide.
9 - 14 1 each 8.3520.8 carbon ±45º, 30 mm x 70 mm.
15 1 8.4548.60 glass Twill 2/2 ±45º
Figure 2: Layers of Cloth in the Flap Bottom Shell
AIRCRAFT
DA 40 Series
AMM
Wings
Doc # 6.02.01
Rev. 5 57-50-00 Page 205
20 Sep 2007
2
3 6
4 7
5
2
3
4
5
8
7
Item No. Layers Reference No. Type Remarks
2 1 8.4548.60 glass twill 2/2 ±45º
3 2 8.3520.8 carbon ±45º, 80 mm x 80 mm.
4 1 8.3520.8 carbon ±45º
5 1 H 60 3 mm rigid foam
7 1 8.3520.8 carbon ±45º
8 1 8.4548.60 glass twill 2/2 ±45º
Figure 3: Layers of Cloth in the Flap Top Shell
AIRCRAFT
Wings DA 40 Series
AMM
Page 206
20 Sep 2007 57-50-00 Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Wings
Doc # 6.02.01
Rev. 5 57-60-00 Page 1
20 Sep 2007
Section 57-60
Aileron
1. General
This Section tells you about the aileron structure. Refer to Section 27-10 for data about the aileron
control system.
AIRCRAFT
Wings DA 40 Series
AMM
Page 2
20 Sep 2007 57-60-00 Doc # 6.02.01
Rev. 5
Aileron Leading Edge
Aileron Hinge Plastic Plug
Flanged
Bush
Access
Hole
Access
Hole
Aileron Horn
Aileron
Structure
Mass
Balance
Top Shell
Bottom
Shell
Figure 1: Aileron Structure and Assembly
AIRCRAFT
DA 40 Series
AMM
Wings
Doc # 6.02.01
Rev. 5 57-60-00 Page 3
20 Sep 2007
2. Description
Figure 1 shows the aileron structure. Each aileron has these components:
A. Bottom Shell
The bottom shell has inner and outer GFRP skins. A layer of carbon fiber cloth covers a large part
of the inboard area of the outer skin. The skins bond to a rigid plastic foam core. The leading edge
of the shell bends up to form a web. It then curves forward to form a shroud which seals the gap
between aileron and wing when the aileron moves down.
The ends of the bottom shell also bend up to close the ends of the aileron. The leading edge, the
ends and the area where the horn attaches have more carbon fiber cloth to give more strength and
stiffness.
B. Top Shell
The top shell has inner and outer GFRP skins. A layer of carbon fiber cloth covers a large part of
the inboard area of the outer skin. The skins bond to a rigid plastic foam core. The top shell bonds
to the bottom shell.
C. Aileron Horn
The aileron horn is an aluminum alloy component. Three bolts attach the horn to the bottom surface
of the aileron. A small hole in the leading edge of the aileron gives access to the front attaching
nuts and washers. The horn also makes one of the aileron hinges.
D. Aileron Hinges
Each aileron has three hinges (as well as the aileron horn). Two bolts attach each hinge to the
leading edge of the aileron. A small hole in the middle of the hinge gives access to the attaching
nuts and washers. Each hinge has a flanged bush at the inboard end. A plastic plug seals the
outboard end.
% E. Aileron Mass Balance
% Each aileron has a paddle on the outboard end. To balance the mass of the aileron behind the
% hinge line, the leading edge of the paddle is made from heavy metal.
AIRCRAFT
Wings DA 40 Series
AMM
Page 4
20 Sep 2007 57-60-00 Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Wings
Doc # 6.02.01
Rev. 5 57-60-00 Page 201
20 Sep 2007
Maintenance Practices
1. General
These maintenance practices tell you how to remove and install the ailerons. Refer to Section 27-10
for the aileron control setting procedure.
2. Remove/Install an Aileron
A. Remove an Aileron
Detail Steps/Work Items Key Items/References
(1) Disconnect the aileron push rod from the aileron
horn:
S Remove the nut and washer from the bolt
which attaches the push rod to the horn.
S Remove the attachment bolt and washer from
the horn.
Hold the aileron.
(2) Remove the 4 hinge pins from the aileron hinges
and the aileron horn:
S Remove the roll pins which locate the aileron
hinge pins.
S Move the hinge pins inboard, and clear of the
hinges.
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