Method for fabricating an aircraft control surface

A method for fabricating a control surface, comprising:

• positioning a shell about a tool defining an internal channel and a hollow trailing edge region, the shell comprising an upper shell portion and a lower shell portion of the control surface, the internal channel runs longitudinally between a leading edge end of the tool and a trailing edge end of the tool, the hollow trailing edge region is disposed at the trailing edge end of the tool and runs laterally between and to a first sidewall of the tool and a second sidewall of the tool, and the internal channel and the hollow trailing edge region are located laterally between the upper shell portion and the lower shell portion;
• injecting a resin into the hollow trailing edge region to fill the internal channel and the hollow trailing edge region;
• containing the resin laterally between the upper shell portion and the lower shell portion;
• and
• cooling the resin to form a stringer connected to the upper shell portion and the lower shell portion and a solid trailing edge region connected to the stringer and to the upper shell portion and the lower shell portion;
• wherein:
• the first sidewall is located at a first side of the tool and extends longitudinally between the leading edge end and the trailing edge end;
• the second sidewall is located at a second side of the tool and extends longitudinally between the leading edge end and the trailing edge end;
• the tool includes a first block defining a longitudinal direction running between the leading edge end and the trailing edge end, the first block is spaced laterally from the first sidewall to form a first closeout channel therebetween, the first closeout channel extends longitudinally between and to the leading edge end and the hollow trailing edge region;
• and
• the tool includes a second block positioned laterally adjacent the first block and spaced a lateral distance from the first block to form the internal channel.