Completed Flap Actuation System (Section 34)

Drilled the tiny hole in the linear actuator rod for safety wire. First attempt broke through. Second attempt, I ignored Van’s instructions and started by drilling a hole in the end. Then drilled a hole from the side to meet up with the first hole. Then final drilled at an angle to eliminate the right angle and allow the safety wire to slide through.

img_3821

 

Greased up the torque tubes and inserted into the bearing blocks on either side. Then I bolted them to the flap crank in the middle. Finally, I bolted the flap motor in place and tested with a 9-volt battery. Worked perfectly.

 

Today’s Time (hours): 2.0
Fuselage Time (hours): 173.0
Total Time (hours): 627.5

Completed Rudder and Brake Systems (Section 33)

Installed the links that attach the rudder cables to the rudder pedals. Riveted the rudder cable fairleads in place. Not pictured, I also bolted in the four adel clamps that hold the plastic rudder cable routing tubes in place. This was a huge pain in the ass. Very little room to get fingers in to get the nuts started. Plus the angle of the tunnel cants the bolts in toward the adjacent structure making it hard to get a socket or wrench on the nuts. But futzed with it long enough and got it done.

 

Today’s Time (hours): 2.0
Fuselage Time (hours): 170.0
Total Time (hours): 624.5

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

 

More rib work

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

img_2266

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

img_2267

There are a whole bunch of bolts in the spars.

img_2268

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

img_2271

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

 

Got Organized

Sorted all the rivets and hardware from the bags they arrived in into the parts organizers I picked up. Used the Dymo Rhino to label everything.

 

Added the wing and options plans to the plans binder.

img_2191-1

Rearranged the shop and re-covered the work benches with new paper.

 

Unwrapped the spars and put them up on the work benches.

img_2195

 

Ready to build!

Today’s Time (hours): 4.0
Wing Time (hours): 10.0
Total Time (hours): 221.0