Examples of Ercoupe Aileron and Aileron Horn Corrosion

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Aileron with pushrod attached. Please note the missing rivets which have popped off. Also note that this aileron was painted after the loss of the rivets.

This is the spar side of the aileron. Again note the loss of rivet heads from the aileron horn. Again, this surface was painted in this condition.

This is the inside of the 16013 aileron control horn. Please note the rust on the bottom (right side in the picture). The attached rib also shows a fair amount of surface corrosion.

This is another view of the aileron control horn. There is significant rust that has developed between it and the aluminum spar and skin of the aileron. This is the combined effects of dissimilar corrosion and condensate wicking its way between the skin and fitting.

Here is an interior view of the aileron with the control horn removed. Note the corrosion in the inboard side of the aileron butt rib.

Another view of horn and rib.

Contrast the above pictures with an new 415-16013-R Aileron control horn.

Here is the F52034 Aileron push rod with rod ends removed. Note the quantity of rust knocked loose from the inside.

Same tube after bead blasting. The more aggressive removal of surface debris from the media clearly exposes a hole that has developed through what would have been the bottom side tube.

Mike Sellers, UNIVAIR