Figure 3: Layers of Cloth in the Flap Top Shell
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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.
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Aileron Hinge Plastic Plug
Figure 1: Aileron Structure and Assembly
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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.
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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. 
(3)  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.  Support the aileron assembly! 
(4)  Carefully move the aileron aft, and clear of the airplane. 

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B. Install an Aileron
DA 40 Series

Detail Steps/Work Items  Key Items/References 
(1)  Make sure that the hinge pins are clean and not damaged. 
(2)  Put the aileron into position on the airplane. 
(4)  Install the 4 hinge pins in the hinges and aileron horn: S Push the hinge pins into position from the inboard side. S Align the holes in the hinges with the holes in the hinge pins and install the roll pins.  Make sure that there is a gap of 0.5 -2.5 mm (0.002 - 0.010 in) between the faces of the hinge at the horn and a gap of 1 - 3mm (0.004 - 0.012 in) between the faces at the other hinges. hinges. 
(5)  Install the bolt which attaches the aileron push rod to the aileron horn: S Install a washer on the bolt. S Push the bolt through the horn and the push rod. S Install the washer and the nut on the bolt. 
　
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