Aileron assembly continues

Dimpled the leading and trailing edge holes in the top and bottom skins as well as the holes in the main ribs attached to them. Dimpled all the holes in the leading edge skins as well as the spars.

 

Machine countersunk the trailing edges.

img_2785

 

Riveted the skins to the nose ribs.

 

Blind riveted the spars to the nose ribs.

img_2789

 

Riveted the top and bottom skins to the nose assembly of the left aileron. Riveted the top and bottom ribs together. Riveted the nose skin to the counterbalance.

 

Prepared the left trailing edge by wiping it down the alcohol and applied the VHB tape to both sides. Then set it in place in the aileron and weighted everything down while resting the edge on a piece of angle iron. I remove the top backing tape by working my way across the aileron by removing a handful of clecos peeling the tape then replacing them with the next handful of clecos down the line until the whole backing tape was removed. I let the tape set up for a while and repeated the process for the bottom.

 

While the VHB tape sets up on the left aileron, I got started on assembling and riveting the right aileron. Got as far as riveting the top skin in place.

 

Today’s Time (hours): 6.0
Wing Time (hours): 185.5
Total Time (hours): 397.5

 

Started work on the ailerons

Screen Shot 2019-06-09 at 1.00.08 PM

Picked and inspected all of the aileron parts. I peeled the protective blue vinyl off of all the parts. Cut apart all of the doublers, hinges, ribs, and stiffeners on the bandsaw. Deburred everything on the Scotchbrite wheel. Dimpled all the ribs and stiffeners with the pneumatic squeezer. Machine countersunk the hinges and doublers.

Everything is ready for scuffing and primer.

 

Today’s Time (hours): 4.0
Wing Time (hours): 171.0
Total Time (hours): 382.0

 

…And tanks are on hold again

Same drill as yesterday… Match drilled the right J-channel stiffener and machine countersunk the skin for the tank baffle rivets.

img_2660

Then I started dimpling the skins. I started by using the squeezer to dimple all the holes it could reach. I caught one hole off center. Then moved on the second skin. I got through the all the ones with the squeezer and then moved to the DRDT and had the skin pop off of the dimple die just as I was pulling the handle. This created an extra hole about 2 mm from the original hole. I could probably salvage both of these issues if this were a regular skin but I’d rather not chance leaky tank skins. So ordered replacements from Van’s. Not my best day of building.

The good news is I’m not stuck waiting on the replacement parts. I can move on to the flaps and/or ailerons in the meantime. Could have been worse.

Today’s Time (hours): 2.0
Wing Time (hours): 144.0
Total Time (hours): 355.0

 

 

Work resumes on the tanks

I received the J-Channel that that I ordered from Van’s. I cut it to length with a cut-off wheel in the Dremel. Then cleaned up the edges on the Scotchbrite wheel. I measured and marked the centerline. Drilled the starter hole. Clecoed it in place and match drilled the rest of the holes, clecoing as I went.

 

I clecoed the baffle in place and machine countersunk the corresponding rivet holes in the tank skin.

 

I disassembled everything final drilled the #19 holes in the skin and then deburred them as well as the holes in the j-channel. I dimpled the J-channel with the pneumatic squeezer.

In other news… My propeller was delivered! It’ll be a while before I need it but ordered it at the same time as the engine to get a discount. The engine has a much longer lead time. Expecting it to show up mid October.

 

 

Today’s Time (hours): 2.0
Wing Time (hours): 142.0
Total Time (hours): 353.0

 

 

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.

img_2618

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.

img_2619

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.

img_2620

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.

img_2621

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

img_2622

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

img_2624

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

img_2627

And then repeated the whole process for the right wing.

img_2628

This completes section 17–Outboard leading edges!

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

 

 

Work continues on Fuel Tanks

Final drilled the tank attach Z brackets and machine countersunk the nutplate attach holes. I cut the brackets apart on the band saw and cleaned up all the edges on the scotchbright wheel. I riveted the nutplates in place with the squeezer.

 

 

I machine countersunk the fuel filler flanges.

 

 

I separated the shims with snips and deburred on the scotch bright wheel. I clecoed the the shims to the tank attach brackets and trimmed the ends to be flush with the brackets with snips and cleaned up the edges on the scotchbright wheel. I final drilled all the holes in the shims and dimpled them with the squeezer. I machine countersunk all the holes in the flanges of the attach brackets.

 

 

I came up short on J-channel. Not sure whether I didn’t cut the stock I had efficiently when making up the wing stiffeners or if I missed something in inventory. Either way I don’t have anything long enough to make the two 54″ tank stiffeners. I ordered a couple more pieces from Van’s. Should be here next week some time.

 

Today’s Time (hours): 3.0
Wing Time (hours): 130.0
Total Time (hours): 341.0