Rinse, repeat, right spar complete

Match drilled the J channel to the spar.

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Machine countersunk the nutplate attach holes.

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Riveted in the nutplates

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Countersunk the screw holes.

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Machine countersunk all the skin attach holes.

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Riveted in the nutplates at the tip end of the spar.

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Riveted the doubler to the spar and installed the tank attach nutplates.

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Final drilled, deburred, scuffed and primed the aileron bell crank brackets

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Installed and torqued the aileron bell crank brackets.

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Right spar done!

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Today’s Time (hours): 4.5
Wing Time (hours): 21.5
Total Time (hours): 232.5

 

Left spar complete

Riveted the spar to the doubler with the 5 AN470 rivets using the squeezer. Then shot the tank attach nutplates using the gun.

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Final drilled and deburred the left aileron brackets.

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Scuffed and primed the aileron brackets with rattle can.

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Installed and torqued the aileron brackets to the spar.

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Put up the left spar and moved the right spar to the bench. Hopefully I’ll get that one knocked out tomorrow.

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Today’s Time (hours): 1.0
Wing Time (hours): 17.0
Total Time (hours): 228.0

 

Countersunk ALL the holes

Countersunk the tank attach screw holes.

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Installed the inspection plate nut plates and countersunk the screw holes.

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Countersunk all the skin attach holes.

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Installed the snap bushings and the the four nutplates at the tip end of the spar.

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Today’s Time (hours): 2.0
Wing Time (hours): 16.0
Total Time (hours): 227.0

 

Attach bottom rudder fairing

Last night I put a layer of glass over the foam in the VS tip.

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This morning, I trimmed and sanded the edges.

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I filled with a thick mixture of glass micro bubbles and epoxy resin.

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I set aside the VS tip to cure and got started attaching the bottom rudder fairing. I measured and marked the fairing and match drilled #40 and clecoed in place.

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I used a nut plate, a #6 screw and a rivet as a drill jig.

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I dimpled all the nut plate attach holes with the squeezer. I needed the close quarters dimple dies for the aft-most holes.

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I dimpled the nut plates.

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I machine countersunk the rudder horn bracket. It’s too thick to dimple.

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I riveted the nut plates in place. I made the aft-most hole too close to the aft edge of the attach strip. So I cut one ear off of the nut plate.

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I machine countersunk the fiberglass for #6 screws.

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Everything went together just fine.

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I disassembled and started work on the doubler for the tail light. I centered and taped it in place. I drilled the #30 holes and clecoed.  I ordered a #43 drill and a 4 40 tap from amazon for the other two holes.

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Today’s Time (hours): 3.0
Empennage Time (hours): 209.5
Total Time (hours): 209.5

 

Riveted aft deck

The nut plates and new static line that I ordered from Van’s showed up today. I installed the static line.

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Riveted the nut plates in place.

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Riveted the aft stiffeners.

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Countersunk the upper cover plate attach holes.

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Installed the left cover plate. The other one is on it’s way from Van’s. I bought some stainless screws to install the cover plates.

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I riveted the aft deck in place.

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Today’s Time (hours): 3.0
Empennage Time (hours): 180.0
Total Time (hours): 180.0

 

Finished riveting side skins and installed systems

Finished riveting the side skins! Remy came down and bucked that last row that I couldn’t reach solo.

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Ran the rudder cables, wiring harness, and ELT antenna cable.

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Remy helped rivet the rudder stops.

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Installed the rudder cable guide blocks.

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Installed the nut plates along the longerons. I didn’t rivet the nut plates for the cover plates because I decided to use countersunk screws and needed to order the correct nut plates from Van’s.

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I installed the static ports. Here’s one from the outside.

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…and from the inside. The static ports are actually pop rivets. I set the rivets and then used the broken off part of the mandrel to drive out the part that remained in the rivet.  I drilled a 1/4″ hole in a piece of scrap wood and used it as a backing block and tapped the mandrel out with a small hammer.

After I took this picture, I added a fillet of silicone around the tube and fitting per the instructions.

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While preparing to install the static system, I wasn’t paying attention to the instructions and cut the polypropylene tubing instead of the clear tubing. So I ordered a replacement from Van’s along with my nut plates.

 

Today’s Time (hours): 8.0
Empennage Time (hours): 170.0
Total Time (hours): 170.0