Much progress on rear spar

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.

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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.

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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.

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

Started the wing build

Cut the J channel to the specified lengths with the Dremel tool and a cutoff wheel.

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Clamped the J channel to flange leaving it 1/16″ proud of the flange.

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Drilled and clecoed the J channel.

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Flipped the lower J channel to the upper flange to finish the holes where the nut plates were on the lower flange. I marked the J channel and set aside for later when the skins go on.

Today’s Time (hours): 2.0
Wing Time (hours): 12.0
Total Time (hours): 223.0

 

Attached vertical stabilizer tip

I final drilled all the holes to #30, dimpled them, machine countersunk the holes in the fiberglass, and blind riveted the tip to the VS. I detached the rudder from the VS and put the VS aside. Won’t be needing it again for a long time.

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I marked the rudder bottom fairing and cut the hole for the tail light with the Dremel tool.

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Used the sanding drum on the Dremel to finish up the hole.

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I primed the outside of the doubler with SEM rattle can primer.

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I mixed up some flox and used it to adhere the doubler to the rudder fairing.

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I blind riveted it in place. I’ll clean it up with sand paper once it has cured.

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Today’s Time (hours): 1.5
Empennage Time (hours): 211.0
Total Time (hours): 211.0

 

Fiberglass work on HS tips

Jared came by with all of his fiberglass stuff and showed me how to close out the horizontal stabilizer tips. I am so grateful to have someone who built the same plane as well as a couple of others that’s willing to help me out as I am learning to build my first plane. Thank you Jared!

We started by attaching the elevators to the hs on the bench. I drilled and clecoed the elevator tips that I had trimmed and fit yesterday to the elevators. Then we trimmed and fit the HS tips to the horizontal stabilizer. We drilled and clecoed them in place and trimmed the trailing edge to match the profile of the leading edge of the elevator tip with a 1/8″ gap.

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Then we trimmed and fit the HS tips to the horizontal stabilizer. We drilled and clecoed them in place and trimmed the trailing edge to match the profile of the leading edge of the elevator tip with a 1/8″ gap. We removed the tips and cut out a foam backer and sanded it to fit into the HS tip.

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I traced the inboard edge of the tip on some glass cloth and cut it out with shears.

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We used West Systems epoxy with the fast hardener. First we mixed up a batch of epoxy and incorporated glass micro bubbles into the resin to make a thick paste that we used to glue the foam in place.

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Then we mixed up another batch of epoxy and laid the glass cloth over the foam. I used a brush to impregnate the cloth with resin and set it into place. It’s rare that I get a picture of me actually building my plane! Photo credit to jared. I had the mask on to work with the micro bubbles. it’s powder fine and super light so it disperses into the air easily and probably isn’t very good to breath.

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And here are the HS tips setting up. Once they’ve cured I’ll fill them with micro and sand them to match the profile of the leading edge of the elevator.

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Today’s Time (hours): 4.0
Empennage Time (hours): 200.0
Total Time (hours): 200.0

 

Trimmed and fitted the elevator and rudder tips

As much as I enjoyed looking at the aft fuselage with the tail feathers attached progress must continue! I remove the rudder, elevator, vertical stabilizer and horizontal stabilizer. I trimmed and fitted the elevator and rudder tips using a Dremel with a diamond cutting wheel, files and 60 grit sand paper.

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I also received the molex pins I ordered from Mouser so I fixed the wire I accidentally yanked out of the aft wiring harness molex connector.

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Tomorrow Jared will teach me how to fiberglass and we’ll close out the VS and HS tips. I’ll need to drill, dimple, countersink and rivet/screw the rudder and elevator tips as well.

Today’s Time (hours): 3.0
Empennage Time (hours): 196.0
Total Time (hours): 196.0