Started assembling the lower skins and muffler shroud.

Dimpled the bottom skins and riveted the com antenna doublers and skin stiffeners to them. I’m only installing a single com radio so I only drilled out the right side skin for the antenna. The left side I installed some rivets to fill the starter holes. I did install the left side antenna doubler in case i want to add another radio later. I can just drill out the rivets and upsize the holes to install another antenna.

 

Dimpled the muffler shroud parts. Riveted the doublers and muffler hanger brackets to the shroud sides. Riveted the nut plates to the fuel pump brackets and then riveted the brackets to the shroud ramp.

 

Today’s Time (hours): 2.0
Fuselage Time (hours): 65.0
Total Time (hours): 519.5

 

Continued assembling the firewall

Riveted the angles and lower gusset to the right firewall side. Used tank sealant to Seal the top of the firewall to the sides and clecoed in place along with the top firewall angle and riveted them together. Clecoed the tunnel sides to the firewall assembly. Sealed the firewall center to the sides and top and clecoed in place. Clecoed the upper top angle and gussets in place. Final drilled the nose gear brackets.

 

Today’s Time (hours): 2.0
Fuselage Time (hours): 61.5
Total Time (hours): 516.0

 

Dimpled the bottom skin and riveted stuff to it.

Dimpled the bottom skin. Today’s word of the day: unwieldy.

 

 

Riveted the doublers and stiffeners to the bottom skin.

 

 

Dimpled the gear brace bracket and machine countersunk the gear brace bars. Riveted the gear brace assembly together and then riveted it to the skin.

 

 

Clamped the lower fuselage substructure to the bench and clecoed the skin to it. Ready for riveting.

 

 

Today’s Time (hours): 6.0
Fuselage Time (hours): 37.0
Total Time (hours): 491.5

 

Assembly continues

Fluted the outboard seat and baggage ribs to mach the curve of the bottom skin. Riveted nut plates to the seat ribs.

 

Bolted and riveted the seat ribs to the bulkhead assembly.

 

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Riveted the seatbelt lugs and routing angles to the baggage ribs.

 

Riveted the aft bulkhead to the seat rib assembly. Drilled and riveted the doubler to the bulkhead. Fabricated and riveted together the idler bearing assembly and riveted to the bulkhead.

 

Clecoed the bottom skins together and match drilled some holes. Cut the landing gear leg openings in the forward skins. Machine countersunk the doublers and dimpled the skin stiffeners. Drilled the 9/16″ hole in the skin with a step drill. This hole will be used to mount the transponder antenna.

 

 

Today’s Time (hours): 5.0
Fuselage Time (hours): 31.0
Total Time (hours): 485.5

 

Wings are complete!!!

Completed the repair to the attach hole that I blew out last week. The fiberglass and micro cured up nicely. I sanded it flush, re-drilled and countersunk the holes, and riveted the nut plate on.

 

The molex connectors that I ordered from McMaster arrived so I inserted the pins and bundled the wires with wire ties.

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This completes construction of the wings! Very excited to move on to the fuselage.

 

Today’s Time (hours): 0.5
Wing Time (hours): 298.5
Total Time (hours): 450.5

 

Completed left wingtip–Almost

All the things I did to the right wing yesterday, I did to the left wing today.

 

 

Thought I was finally at th end of the wings… but ran into another snag. When I was countersinking the screw holes in the tip, I hit a thin spot in the fiberglass and the countersink caught and made a giant hole. So I made a fiberglass patch. I’ll fill in the other side with some micro once the patch sets up. Then I can install the final nut plate and be done with the wings!

 

 

Traveling this week. So I will begin work on the fuselage next weekend.

Today’s Time (hours): 5.0
Wing Time (hours): 298.0
Total Time (hours): 450.0

 

Completed Right Wingtip

Laid out the cut the left and right wing tips. I made over-ran on of the cuts by an inch or so on the left wing. So I did a little patch and fill with some fiberglass and micro and set it aside to cure. Then continued work on the right wingtip.

 

Cut and installed the nav light lens.

 

Installed the nav/strobe light. Used the template from the plans to drill the wingtip. Terminated the wires with Molex .062 pins. Unfortunately Vans provided a 4-pin molex housing instead of the 5-pin one that matches the wiring harness in the wing. <sigh> Now I get to pay $10 in shipping for two $1 moles housings. Mounted the bracket and installed the light. Tested it out with a 9-volt. That sucker is bright!

 

Fit the wingtip to the wing and set it in place with a ratchet strap. Match drilled the holes from the wing skins to the wingtip. Final drilled and dimpled the holes in the wing for #6 screws. Final drilled the screw holes in the wing tip and then used a nut plate, a screw, and a cleco as a drill jig to drill the nut plate attach holes. Machine countersunk the screw and rivet holes and riveted the nut plates in place.

 

Fit the wing tip rib to the wingtip. Laid out and match drilled rivet holes. Riveted the rib in place.

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Bam! Right wingtip done.

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Today’s Time (hours): 8.0
Wing Time (hours): 293.0
Total Time (hours): 445.0