Ailerons are done!

Riveted bottom skin to the right spar and riveted the top and bottom main ribs together.

Prepped the trailing edge extrusions and applied VHB tape to both sides. Clecoed in place and removed the backing. After the tape set up, I lightly set rivets with the squeezer then back riveted double flush.

Ailerons are complete. This completes all of the control surfaces on the airplane.

My replacement fuel tank skins should be here Thursday. Hoping to get the tanks assembled next weekend.

Today’s Time (hours):	3.0
Wing Time (hours):	189.0
Total Time (hours):	341.0

Finished the left flap

Worked on both left and right flaps simultaneously; performing each step on one then the other. Riveted the top skins and nose skins to the spars and then to the ribs. I back riveted the aft-most two holes in each rib.

Clecoed then riveted the bottom skins and nose skins to the spars. I had to stick my arm down between the skins, slightly pulling back the bottom skin to be able to back these rivets. Glad I deburred well. My arms were pretty well scraped by the end of this step.

Final drilled #33 and blind riveted the nose skins to the nose ribs.

Applied 3M double-sided VHB tape to the trailing edge extrusions. I clecoed the extrusions in place in the left wing, removing the bottom backing from the tape as I went. I let the VHB adhesive set up for an hour or so and remove the top backing form the tape; removing and replacing clecos as I went.

I let the top tape set up for a couple of hours. I clecoed and taped the trailing edge into the right wing at this point and moved on to riveting the left wing while the bottom tape set up.

I used the squeezer to just barely set rivets in the trailing edge. Then used a mushroom set in the gun with a back rivet plate to fully set the back of the double flush rivets.

I final drilled #33 all the bottom skin/rib holes and blind riveted. I used the squeezer to set solid rivets in the inboard and outboard end ribs. I installed the rod end for the flap actuator. Left wing done!

I removed the backing form the top tape on the right trailing edge. I’ll finish the right flap up in the morning.

Today’s Time (hours):	6.0
Wing Time (hours):	166.0
Total Time (hours):	377.0

Installed landing lights and lenses

Cut the plexiglass lens to 3/4″ larger than the opening in the wing using the Dremel with a diamond dust blade. Cut like buttah.

Covered the lens with tape to protect it. Put in in place within the wing and traced the opening onto the tape. I lined up the backing places and marked the tape with the finished cut lines. I cut to final size with the Dremel and sanded the edges smooth with a sanding drum in the drill press.

Set the lens into place and used the tape “leash” i made on the front of the lens to pull it tight against the inside of the skin. Drilled and clecoed all th holes with a #30 plexi bit.

Remove the lens from the wing and removed the tape. I countersunk the holes with 100 degree zero-flute countersink bit in the electric drill. I deburred the back side of the holes with a single turn of the same bit.

I used VHB double stick tape to secure the backing plates to the lens.

I installed the landing light onto the bracket that I had riveted into the wing in an earlier step.

I secured the lens in place with #6 stainless screws.

And then repeated the whole process for the right wing.

This completes section 17–Outboard leading edges!

Today’s Time (hours):	4.0
Wing Time (hours):	137.0
Total Time (hours):	348.0

Did the Nasty

Decided to just get this out of the way tonight…

I went through three changes of gloves and still managed to get it on my hands.

Prepped the scuffed surfaces with isopropyl.

Sealed the trialing edge ribs in place. Peeled the tape and stuck the top skins to the trailing edges. Weighted down the aft section to ensure good bond of the skins to the ribs. The sealer cures in six hours according to the data sheet. So should be riveting the trailing edge and finishing up tomorrow.

Bent the trim tab hinge pin per the plans.

Today’s Time (hours):	1.0
Empennage Time (hours):	119.5
Total Time (hours):	119.5

Riveted Spars and Ribs in Left Elevator

I started off the day by taping the trailing edge to the bottom right elevator skin with the 3M VHB. tape.

I also completed the trim servo assembly. I need to order a crimper to terminate the wires from the trim servo with the supplied micro molex connector. I also need to get a label maker to label all the terminations.

Then my new squeezer set from Aircraft Spruce showed up. It’s nice having them relatively local. If I order by 4:00 they’ll ship same day and shipping via UPS ground gets it here next day from Peachtree City.

With the new squeezer sets I was able to complete the riveting of the hinge portion of the skin to the aft spar.

I essentially completed all of the steps that I did to the right elevator yesterday to the left elevator today. So now both elevators are ready to have the aft ribs glued and the trailing edges riveted.

Today’s Time (hours):	6.0
Empennage Time (hours):	118.5
Total Time (hours):	118.5

Assembled Trim Tab

Bought a 3/4″ MDF panel at Home Depot. Leveled it out on the bench and shimmed the dead spaces with sheets of paper to create a flat surface.

Prepped the skins, spar, and trailing edge with isopropyl. Mixed up a small batch of fuel tank sealant and put a thin layer on each side of the trim tab ribs and set them in place. I used the 3M VHB tape on both sides of the trailing edge. Used clecos to align it with the bottom skin and set it in place. Then I clecoed the top skin in place along the spar and trailing edge. I peeled the paper from the VHB tape between the top of the trailing edge and the top skin removing clecos as I went to avoid tearing the paper. I replace the clecos to clamp the whole sandwich together while the tape sets up.

The sealant is ridiculously sticky and smells like ass.

I riveted the top skin and hinge to the spar.

All done!

Weighted down the skin with a board and some 2×4’s to ensure contact between the skins and the ribs until the sealant sets up. The spec sheet says there is a 6 hour cure time for the B 1/2 sealant I used.

Today’s Time (hours):	1.5
Empennage Time (hours):	101.5
Total Time (hours):	101.5

Riveted everything together

I finished back riveting the stiffeners to the skins. I had one oops where a rivet got cockeyed just before I drove it. It left a ding in the skin but didn’t penetrate. I debated replacing the skin but opted to move on.

I used 3M F9460PC double stick VHB tape to secure the trailing edge extrusion to the skin and clecoed it together. I put some long rivets through every tenth hole or so, put the tape on both sides of the wedge, and used the rivets to properly register the taped wedge to the right skin. Then I clecoed it in place and removed the rivets.

I riveted the stiffeners and shear clips together. I removed the backing from the other side of the tape while I pried the skins slightly apart so the strip didn’t tear. I removed clecos as I worked my way to the top of the trailing edge. I pressed the left skin into the tape and clecoed every hole.

I mounted the counterbalance. I had to file a bit off of the forward corners to clear the shop heads of the rivets holding the counterbalance rib in place. I riveted the skin to the spar, and riveted everything else except the trailing edge. That will be tomorrow’s adventure.

I neglected to shoot progress photos along the way but here’s the result of today’s work…

This is the tape I used…

Today’s Time (hours):	6.0
Empennage Time (hours):	36.0
Total Time (hours):	36.0