Fitted the aileron trim and inboard bottom skins

I finished inventorying and stowing parts from the fuselage kit and avionics.

Crimped the pins onto the aileron trim wires, added a heat shrink tube, and inserted them into the molex connector.

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I centered the set the aileron trim using a 9-volt battery to drive the servo. I set the  assembly in place on the wing and set the aileron to the neutral position. Then I marked the point where the aileron trim arm rested over the  push tube. I remove the push tube and located the tabs 6 inches either side of the center mark. I match drilled and blind riveted them to the push tube. I attached the springs to the tabs.

 

I clecoed the inboard bottom skins in place on the wings. Ready to rivet.

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Today’s Time (hours): 4.0
Wing Time (hours): 264.0
Total Time (hours): 416.0

 

Finished assembling right tank.

Added a bead of tank sealant for the baffle. Clecoed the baffle in place. Riveted the baffle to the ribs and then riveted the z-brackets in place. Then riveted the baffle to the skin.

 

Installed the fuel drain, the fuel sender, AN fittings, and the fuel cap.

 

Machine countersunk the holes in the tank attach bracket for #8 screws.

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The right tank is now complete and once the sealant has cured, I can pressure test it. Hoping to get the left tank to the same state tomorrow.

 

Today’s Time (hours): 3.0
Wing Time (hours): 226.0
Total Time (hours): 378.0

 

Flaps Completed

Same drill for the right flap… Just barely set the trailing edge rivets with the squeezer then set the shop heads flush with a mushroom set in the gun and a back riveting plate. I riveted the bottom skins with blind rivets. Then I installed hardware.

 

Flaps complete!

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Emailed Van’s about my tank skins and heard back on Friday. The right skin is back ordered so they estimate that they will ship end of next week. I’ve got plenty to keep me busy until then… On to the Ailerons.

Today’s Time (hours): 1.0
Wing Time (hours): 167.0
Total Time (hours): 378.0

 

Finished the left flap

Worked on both left and right flaps simultaneously; performing each step on one then the other. Riveted the top skins and nose skins to the spars and then to the ribs. I back riveted the aft-most two holes in each rib.

 

 

Clecoed then riveted the bottom skins and nose skins to the spars. I had to stick my arm down between the skins, slightly pulling back the bottom skin to be able to back these rivets. Glad I deburred well. My arms were pretty well scraped by the end of this step.

 

 

Final drilled #33 and blind riveted the nose skins to the nose ribs.

 

 

Applied 3M double-sided VHB tape to the trailing edge extrusions. I clecoed the extrusions in place in the left wing, removing the bottom backing from the tape as I went. I let the VHB adhesive set up for an hour or so and remove the top backing form the tape; removing and replacing clecos as I went.

 

 

I let the top tape set up for a couple of hours. I clecoed and taped the trailing edge into the right wing at this point and moved on to riveting the left wing while the bottom tape set up.

I used the squeezer to just barely set rivets in the trailing edge. Then used a mushroom set in the gun with a back rivet plate to fully set the back of the double flush rivets.

 

 

I final drilled #33 all the bottom skin/rib holes and blind riveted. I used the squeezer to set solid rivets in the inboard and outboard end ribs. I installed the rod end for the flap actuator. Left wing done!

 

 

I removed the backing form the top tape on the right trailing edge. I’ll finish the right flap up in the morning.

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Today’s Time (hours): 6.0
Wing Time (hours): 166.0
Total Time (hours): 377.0

 

Started riveting the outboard leading edge to left wing

Clecoed the outboard leading edge assembly to the left wing assembly.

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Blind riveted the leading edge ribs to the main spar.

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I set the the wing upright on the workbench and riveted the leading edge skin to the lower flange of the main spar.

I need a bucking partner to get the upper flange. Hopefully Remy will be available tomorrow evening.

Today’s Time (hours): 2.0
Wing Time (hours): 122.0
Total Time (hours): 333.0

 

Riveted outboard leading edge to right wing

Completed the right outboard leading edge by riveting the landing light bracket and J channel stiffener in place.

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Clecoed the outboard leading edge to the right wing.

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Blind riveted the leading edge ribs to the main spar. I couldn’t get the rivet puller square to the river so I fabricated a wedge to safely pull the rivets at an angle. Thanks to Jared for the reminder on this technique. I had originally read about it in section 5 but had forgotten. I ended up using a piece of left over trailing edge wedge. I cut of a small section about half an inch long and drilled a hole in it to accommodate the tail of the blind rivet.

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Riveted the leading edge skin to the bottom flange of the main spar.

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Riveted the leading edge skin to the top flange of the main spar. Remy bucked for me.

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I made a home depot run and picked up a bunch to 2×4’s to construct a wing cradle.

I messed up and stripped a couple of screws that I used to attach the inspection plate to the left leading edge. Need to order a screw extractor.

Today’s Time (hours): 3.0
Wing Time (hours): 116.0
Total Time (hours): 327.0

 

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