Mechanical design · Fabrication
Aileron Table
A nearly 20-foot aircraft aileron adapted into a table with a parametric frame, legs, and aluminum fairings.
Overview
I reverse-engineered an existing aileron and designed a table around its aircraft hinge points, accounting for uncertain measurements and the realities of building a large welded structure.
My contribution
I designed the legs, steel frame, and aluminum fairings in SolidWorks, produced fabrication drawings, and co-fabricated the MIG-welded frame with laboratory engineers. I also prepared waterjet files for the fairings.
Engineering approach
Repeated tape measurements and CAD cross-checks established the geometry. A master wireframe propagated dimensional changes through the assembly in minutes. SolidWorks Weldments sized the angle iron; aluminum stringers support the tabletop. Steel routes loads into the aileron, and fairings cover internal mounts and sharp edges.
Results & current status
The frame was fabricated within a ¼-inch allowance. Fit-and-weld assembly accommodated measurement uncertainty, and I updated CAD to match the built frame. Waterjet files are prepared; aluminum fairing fabrication awaits supplier availability.
Supporting files
Explore the assembly in your browser or download the original SolidWorks package.
ZIP 21.1 MB · GLB 10.1 MB
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