Source: 1996 Beartracks, Bob Barrows

Before covering the ailerons with fabric you will need to install a balance weight. The balance weight in the BEARHAWK aileron is nothing more than an aluminum tube filled with lead and pop riveted into place. Lead is the best material, both weight and cost wise (maybe free), to use for this task as it is easy to work with. The plans show the proper location of the balance tube in the nose of the aileron.

To figure out the amount of lead needed you will have to have the aileron attached to the aileron hinges in its proper location. Taking into account the weight of the fabric and dope (.10 lb/Ft²) to be used, you will place weights on the aileron until it is balanced (see fig 1). The weight of the nose balance is the needed weight for the balance tube.

You may be able to source your lead from a local garage that works on wheels and tires, as most do. Get the used lead weights that wheels are balanced with. You will need a good sized coffee can full of them or about 20 pounds. Don’t worry about the steel clips, they will float to the top when you melt the lead so you can skim them off before you pour. Lead shot works good too, you just have to pay for it. Most gun stores and big department stores will sell shot in 10 – 20 – 50 pound bags. You will also need a stainless steel pot or bowl, check at the dollar store. Bend the pot to a point on one end to make it easier to pour into the tube. Melt the lead in the bowl OUTSIDE over a grill or small fire . DO NOT BREATHE LEAD FUMES!!! You will also need thick gloves (welders gloves are good), goggles and wear long pants. Heat lead to a high enough temperature so as to just brown a wood dip stick about 450°F – 500°F.

Have everything ready before you start so you are not running all over the place. Plug one end of the balance tube and drive that end into the ground. You may wish to brace it further as it will grow much heavier as the lead is added. DO NOT HOLD TUBE AS YOU POUR! Balance tube will just about need to be full from end to end. After cooling, some lead can be drilled out from each end if too heavy. Up to 10% over balance is fine. Save any left over lead as you will be balancing the tail surfaces too.

LEAD weighs .41 pounds per cubic inch.