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PmWiki /
RightWingAmount of hours spent on right wing: 59.5 December 4, 2008 - 1h Major milestone reached: wings are done!! I cut the two pieces of hinge pins to length and bend them accordingly. Had some trouble getting them in the combined flap and wing hinge eyes, but after a bit of pushing and pulling it went in.
 
 
December 3, 2008 - 1h As per Van's recommendations, I dimpled the spar brace / skin combination and countersunk the hinge. The countersink didn't have to be very deep, because the dimple in the spar brace didn't stick out as far as normal (probably due to the double dimpling). After that I decided to go with the method where 2 hinge eyes are taken out of the flap hinge and one from the wing hinge. Finally riveted the hinge in place with 4.5 rivets. I had the feeling that the 4's that are specified on the drawing had too small of a shop head. Looks much better with the 4.5's. Tomorrow I'll do the same on the left wing. For the aileron stop I think I will go for this solution.
December 2, 2008 - 1.5h Dimpled and riveted the nutplates for all three access holes. Temporarily installed the small pushrod between the A/P servo and the bellcrank.
Ouch! I noticed that I completely forgot to countersink the rivet holes on the flapbrace before installing the bottom skins! Found some posts (here, here and here) on Van's Airforce about this and will call Van's tomorrow to ask how I can solve this 'small' problem. It seems that both dimpling and countersinking the hinge are options. Note: called Van's and they recommended countersinking the hinge as the material is more than thick enough for that. So I guess that's what I'll do!
December 1, 2008 - 3h Finished riveting the bottom skins on the right wing!
Drilled the flap hinge on the right wing after making sure the alignment with the aileron is perfect (or almost...)
 
Hopefully tomorrow I can finish both wings and start on the fuselage for real :-) That is if Van's new firewall stiffener arrives ones of these days...
November 29, 2008 - 2h Finished riveting the inboard skin and mounted the Dynon A/P roll servo next to the bellcrank.
November 27, 2008 - 1.5h Started riveting the inboard skin on the right wing. I started out on the table to do the first 3 ribs and then moved the wing back to the craddle for easier access. Three of the rivets were still kind of bad and I replaced those with BS-319 blind rivets (have to call Van's on Monday to confirm that's okay).
November 26, 2008 - 1h Reached the 300 hours mark on the wings today. I spent some time on mounting the Dynon servo brackets today. When tightening the lock nut on the bellcrank bracket I noticed that the bellcrank didn't turn smoothly anymore and I took some more of the metal off to give the bellcrank bushing some more breathing space. After that I test-fitted the Dynon servo: it fits perfect!
November 24, 2008 The Dynon roll servo arrived in the mail today! When I've closed up the left wing, I'll start mounting this baby on the right wing spar.
November 18, 2008 - 1h Edge deburred the inboard bottom skin and dimpled all the rivet holes except for the ones where the wing fairing is going to be mounted.
November 17, 2008 - 0.5h Deburred holes in the inboard bottom skin and removed protective plastic.
October 4, 2008 - 1h Edge deburred, hole deburred and dimpled the outboard bottom skin.
September 7, 2008 - 1h Riveted the right flap brace and aileron gap seal onto the rear spar and skin.
 
August 31, 2008 - 4h After a very enjoyable flight to CGE for breakfast today with Michela and Mark, I spent the rest of the afternoon on the aileron brackets, flap brace and aileron gap seal. Deburred and primed all of these parts, riveted the brackets together and mounted them on the rear spar. Seems I have a leak in the bottom valve of my compressor tank; I think it's the rubber seal that is too old.
August 30, 2008 - 4.5h With the help of Adriana we riveted the top skins on the right wing today. When that was done I mounted the lens on the leading edge light and put the wing next to its brother (or is it sister?) in the wing stand. Did the bottom row of rivets on the wing stand which was a lot easier then crawling under the wing like I did last time. Very productive day. I'll have to start on the tank pretty soon now...
 
August 26, 2008 - 3.5h Finished the leading edge light, incl. fitting the lens. Dimpled the right wing rear spar and main ribs. Edge deburred the top skins and prepared them for riveting.
August 25, 2008 - 3h Tonight I riveted the right leading edge on the spar. Used MSP-42 blind rivets again to rivet the ribs to the spar and normal rivets for the skin to the spar. I need to drill out one blind rivet as it did not go in right, but I need to find out how to best do that.
 
I also mounted the HID light in its mount and the driver unit on the back of the mount.
And man, is this light bright! I plugged it into my power supply and let it shine on the garage door:
 
(watch out for not pointing the light up or down more than 45 degrees for the 1st minute of operation and after switching it off as the xevision manual tells you)
August 24, 2008 - 5h Riveted the right leading edge together today. This went a lot smoother and faster than the first one; I guess practice counts :-)
Also cut out the hole for the leading edge landing light and riveted the nutplates to the light mounting plate.
With the help of my neighbors Adriana and John who came by to check out the wings, we dimpled the two top skins. This is definitely a lot easier to do with two or three people than it is alone. I also countersunk the skin holes in the main spar on both sides and primed these with self-etching primer.
August 23, 2008 - 1h Clecod the right leading edge together and deburred edges a bit more.
August 21, 2008 - 1h I primed the right leading edge ribs and the leading edge light parts tonight. This new zinc oxide primer from Aircraft Spruce is SUCH an improvement over the old Tempo stuff! It comes out smooth and leaves a nice layer on the aluminum. The previous Tempo rattlecans were really hard to use and it was hard to get any paint out; and even if it did, it made drops everywhere on the parts. No this is definely working out very nice. Color is a little less bright yellow than it used to be, but I can live with that. Also took the blue sticky materials from the top skins to prepare for deburring and dimpling.
August 17, 2008 - 2h Deburred holes and edges of the leading edge ribs and dimpled them. Alu-etched all of the ribs and the leading edge landing light components. Prepared the two outboard ribs for mounting of the landing light. Took the top skins off and started dimpling the main ribs in the structure.
August 16, 2008 - 1h Deburred holes and edges of the right leading edge skin and dimpled it with the C-frame.
August 11, 2008 - 3h Finished match-drilling the tank skins and tank attach brackets. Riveted nutplates on six of the attach brackets. Riveted nutplates for the 7th bracket on the main spar.
August 10, 2008 - 4h Today I've match-drilled the tank attach brackets to the spar using the checkoway method again.
 
Also started match-drilling the tank skins to the ribs. 
Good day. Got a lot done! August 9, 2008 - 3h Finished match-drilling the top and bottom skins. Clecod the leading edge together and mounted it on the spar. Match-drilled the ribs and the leading edge skin to the spar. Put the inboard rib with the W-423 joint plate in the leading edge and drilled holes. Drilled the hole for the tie-down ring with a unibit.
 
July 30, 2008 - 2h Fabricated the wing walk doubler and drilled it to the inboard top skin. Cleco'd the skins (top and bottom) and the doubler to the spars and ribs and match-drilled half of the holes.
 
And look how straight this all is. Can't be much better than 0 degrees!  
July 29, 2008 - 2.5h Tonight I riveted the main ribs to the main and rear spar and I mounted the structure on the wing stand for skin fitting. Sorry I haven't put any images yet of the right wing, but since they will really be the same as the left wing, I'm not going to bother too much with that. Did I mention already that I'm going to EAA AirVenture this weekend? Looking forward to that!!
July 28, 2008 - 1.5h Primed the other half of the ribs and started to cleco together the ribs with the main and rear spars.
July 27, 2008 - 1h Prepared the other half of the ribs (scotch-brite and alumi-prep) and primed the first half.
July 26, 2008 - 2h Prepared half of the ribs of the right wing today (scotch-briting and edge/hole deburring) and drilled the hole for the electrical conduit in all of the ribs. Also alumi-prepped these ribs in preparation for priming.
July 19, 2008 - 1h Started to cleco the front spar, rear spar and main ribs of the right wing together for match-drilling to the spars.
The workshop suddenly looks very full!
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