More work on rear spar

Final drilled #30 the spar, doublers, rib flanges, and aileron hinge attachments.

Machine countersunk the flange holes where they match up to the doublers.

Machine countersunk the doubler plates. Also drilled the attach hole to 11/32 after this photo was taken. I need to pick up a 3/8″ reamer to finish the attach holes in the fork and doubler once they’re matched up and riveted to the spar.

Dimpled all the #40 holes in both flanges of the rear spar.

Everything is ready to prime and assemble when I get back from Sun n Fun next week. Pretty happy with this weeks progress.

Today’s Time (hours):	1.0
Wing Time (hours):	60.0
Total Time (hours):	271.0

Much progress on rear spar

Screen Shot 2019-05-27 at 10.16.11 AM

Peeled the vinyl from all the parts. Did the minor cutting and fabrication called out in the plans. Cleaned up and deburred all the edges with file, deburring tool, scotch brite wheel, and sandpaper. Scuffed everything with a scotch brite pad.

Assembled and final drilled the aileron hinges. The inboard hinges are from the service bulletin. I’m surprised they haven’t updated the plans yet. Had to follow the SB instructions.

Clamped the spar doublers to the spars and match drilled them.

Drilled out the aileron pushrod hole in the inboard doublers and cleaned them up with the Dremel.

Clecoed the right rear spar together with the wing assembly.

Today’s Time (hours):	4.5
Wing Time (hours):	59.0
Total Time (hours):	270.0

Wing ribs complete

Riveted the forward flanges of all the ribs to the spar with the rivet gun. My riveting seems to be getting better… Didn’t have to drill any out. I set the pressure at the compressor to 75psi for the -4 rivets. This seemed to work really well. I had tried a lower pressure in the past and the manufactured head would get all beat up. At the lower pressure, I had to hit the rivet so many times that I think it was getting work hardened.

I also finished installing the AN3 hardware and torquing to spec. Kinda sorta starting to look like wings…

Picked all the parts (including the service bulletin kit) for the rear spar.

Today’s Time (hours):	2.0
Wing Time (hours):	54.5
Total Time (hours):	265.5

Primed everything and started assembly

Wiped everything down with acetone and then shot primer. I did the spars first, then the ribs in two batches, and finally all the other small parts.

Riveted the flap hinges and hinge ribs to the ribs. I started using the squeezer but it couldn’t reach most of the rivets so just switched to the gun and shot the rest of them.

Assembled and riveted the the torque tube brackets and riveted them to the inboard ribs.

Clecoed the ribs to the spars and reinstalled the AN3 hardware and torqued everything down. I also installed the snap bushing in the systems holes in all the ribs. Many of them were a bit loose. I’ll have to give some thought on how I want to resolve this.

Today’s Time (hours):	7.0
Wing Time (hours):	52.5
Total Time (hours):	263.5

Final drilled ribs to spars and drilled systems holes.

Spent a lot of time finishing the deburring of all the holes in the flanges and finishing dimpling the lower flanges of the ribs.

Clecoed the ribs to the spars and final drilled all the holes in the forward flanges.

Disassembled everything and deburred the rest of the holes.

Measured, marked, and drilled the systems holes with the step drill.

Deburred all the the systems holes.

Ready to prime and assemble ribs.

Today’s Time (hours):	7.0
Wing Time (hours):	45.5
Total Time (hours):	256.5

More rib work

I set the spars on the work benches opposite one another and removed all the bolts.

It went a lot quicker when I remembered I had an impact driver in the tool box.

There are a whole bunch of bolts in the spars.

Back to the ribs… Deburring holes and dimpling the bottom flanges.

Today’s Time (hours):	4.0
Wing Time (hours):	38.5
Total Time (hours):	249.5

Work on the ribs continues

Netflix and scuff! Sophie deburred and scuffed all the ribs while I was traveling this week. Awesome job!

I fluted and straightened all the ribs.

I assembled and final drilled #30 the torque tube bracket assemblies.

I clecoed the torque tube bracket assemblies to the inboard-most ribs and final drilled them to the rib webs.

I clecoed the flap brackets and flap bracket ribs to the inboard and outboard wing ribs and natch drilled all the #30 holes.

Today’s Time (hours):	10.0
Wing Time (hours):	34.5
Total Time (hours):	245.5

Started on the ribs

Screen Shot 2019-05-27 at 10.13.09 AM

Cut and deburred all the rib parts.

Took the blue plastic off al of the ribs.

Final drilled #40 the top and bottom flanges of all the ribs.

Sophie helping out with scuffing and deburring.

Today’s Time (hours):	3.0
Wing Time (hours):	24.5
Total Time (hours):	235.5

Rinse, repeat, right spar complete

Match drilled the J channel to the spar.

Machine countersunk the nutplate attach holes.

Riveted in the nutplates

Countersunk the screw holes.

Machine countersunk all the skin attach holes.

Riveted in the nutplates at the tip end of the spar.

Riveted the doubler to the spar and installed the tank attach nutplates.

Final drilled, deburred, scuffed and primed the aileron bell crank brackets

Installed and torqued the aileron bell crank brackets.

Right spar done!

Today’s Time (hours):	4.5
Wing Time (hours):	21.5
Total Time (hours):	232.5

Left spar complete

Riveted the spar to the doubler with the 5 AN470 rivets using the squeezer. Then shot the tank attach nutplates using the gun.

Final drilled and deburred the left aileron brackets.

Scuffed and primed the aileron brackets with rattle can.

Installed and torqued the aileron brackets to the spar.

Put up the left spar and moved the right spar to the bench. Hopefully I’ll get that one knocked out tomorrow.

Today’s Time (hours):	1.0
Wing Time (hours):	17.0
Total Time (hours):	228.0