Fitting the flaps together

Assembled the inboard and outboard rod end ribs. Clecoed the ribs and doubles together. Match drilled the #40 holes and final drilled the 1/4″ hole. Countersunk the #40 holes on the outboard doublers.

 

Clecoed the ribs to the flap hinges and final drilled all the #30 holes.

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Modified all the main ribs by removing the top forward tab from each with the Dremel and a cutoff wheel. Finished with a bit of sanding to remove the burrs.

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Assembled the flap substructures.

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Trimmed the inboard and outboard trailing edges to final size with the bandsaw and finished on the scotch brite wheel.

 

Clecoed the flaps together.

 

Match drilled the two top holes in each of the nose ribs. I also final drilled all of the holes in the trailing edges.

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Assembled the hardware in the hinge to hold everything in alignment and match drilled the four holes in the  trailing edge of the hinge.

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Disassembled everything.

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Next I need to machine countersink the holes in the trailing edge wedge and the holes I just drilled in the hinges. Then dimple and prime everything.

Today’s Time (hours): 6.5
Wing Time (hours): 152.5
Total Time (hours): 363.5

 

 

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.

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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

 

Horizontal Stabilizer Rear Spar

Started work on the horizontal stabilizer today. The first part involves preparing the rear spar.

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Deburred the rear spar and the rear spar doubler with the Scotch Brite wheel, files, a deburring tool and god old fashioned sandpaper. Got all the edges and lightening holes nice and smooth. Clecoed the rear spar doubler to the rear spar. Final drilled all the holes.

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Clecoed the 8  outboard hinge brackets to the spar and final drilled.

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Machine countersunk the two holes in the center of the spar.

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Fit, clecoed, drilled, disassembled, deburred, reassembled, and riveted the inboard hinge bracket assembly with the flange bearing in the middle.

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Deburred and scuffed everything. Ready for primer. I’m only going to prime the inside of the spar. the outside will be painted when I paint the airplane. I neglected to account for this when I built the VS and rudder. I’m assuming the primer can be stripped from the outside of those spars in preparation for painting.

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Today’s Time (hours): 2.5
Empennage Time (hours): 48.5
Total Time (hours): 48.5

 

Back to the Vertical Stabilizer

Got all my VS replacement parts from Vans and now that I’ve completed the rudder I can go back and finish the VS. Tonight I cut, fit, clecoed, drilled, disassembled, deburred and dimpled all the parts. Next I’ll scuff and prime them and then rivet everything together. I hope to have the VS all buttoned up next weekend.

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Today’s Time (hours): 2.0
Empennage Time (hours): 43.0
Total Time (hours): 43.0