Riveted rear spars to ribs and started on top skins

Riveted the rear spars to the wing ribs. I tried to use the squeezer but it was cumbersome with several different rivet sizes and with the flanges in the way. So I switched to the gun. This was much easier.

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And of course, no section is complete without a few mistakes. I used the wrong size rivets in ribs behind the doublers. I used 4-4’s and needed 4-5’s the shop heads were too thin to be acceptable. So I drilled them all out. Nine rivets in total. I couldn’t punch the rivets out because there was nothing to back them up when I hit them with the punch. So I had to drill them all the way out. I was super careful but the holes are enlarged ever so slightly. If this wasn’t a critical structure, I’d probably just re-rivet it but this area carries the load from the ailerons and flaps. So I’ll go with a larger river to ensure structural soundness. I order some -5 rivets, a #21 drill, and a 5/32″ rivet set from Spruce.

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I clecoed the wing walk doubles and inboard top skins to the spars and ribs.

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I also put in an order with Van’s for some fuel tank sealant.

 

Today’s Time (hours): 2.0
Wing Time (hours): 69.0
Total Time (hours): 280.0

Wing ribs complete

Riveted the forward flanges of all the ribs to the spar with the rivet gun. My riveting seems to be getting better… Didn’t have to drill any out. I set the pressure at the compressor to 75psi for the -4 rivets. This seemed to work really well. I had tried a lower pressure in the past and the manufactured head would get all beat up. At the lower pressure, I had to hit the rivet so many times that I think it was getting work hardened.

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I also finished installing the AN3 hardware and torquing to spec. Kinda sorta starting to look like wings…img_2291

 

Picked all the parts (including the service bulletin kit) for the rear spar.img_2293

 

Today’s Time (hours): 2.0
Wing Time (hours): 54.5
Total Time (hours): 265.5

Did the Nasty

Decided to just get this out of the way tonight…

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I went through three changes of gloves and still managed to get it on my hands.

Prepped the scuffed surfaces with isopropyl.

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Sealed the trialing edge ribs in place. Peeled the tape and stuck the top skins to the trailing edges. Weighted down the aft section to ensure good bond of the skins to the ribs. The sealer cures in six hours according to the data sheet. So should be riveting the trailing edge and finishing up tomorrow.

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Bent the trim tab hinge pin per the plans.

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Today’s Time (hours): 1.0
Empennage Time (hours): 119.5
Total Time (hours): 119.5

 

Riveted Spars and Ribs in Left Elevator

I started off the day by taping the trailing edge to the bottom right elevator skin with the 3M VHB. tape.

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I also completed the trim servo assembly. I need to order a crimper to terminate the wires from the trim servo with the supplied micro molex connector. I also need to get a label maker to label all the terminations.

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Then my new squeezer set from Aircraft Spruce showed up. It’s nice having them relatively local. If I order by 4:00 they’ll ship same day and shipping via UPS ground gets it here next day from Peachtree City.

With the new squeezer sets I was able to complete the riveting of the hinge portion of the skin to the aft spar.

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I essentially completed all of the steps that I did to the right elevator yesterday to the left elevator today. So now both elevators are ready to have the aft ribs glued and the trailing edges riveted.

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Today’s Time (hours): 6.0
Empennage Time (hours): 118.5
Total Time (hours): 118.5

 

Riveted the Forward Spar Assemblies

Riveted the gusset to the left root rib and riveted the inboard and outboard halves of the tip ribs together. Spent a bit of time with a square and hand seamers tweaking to ensure everything is straight.

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Riveted the tip ribs to the spars. Riveted the hinge reinforcement plates and nut plates to the spars.

 

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Clecoed and riveted the counterweight skins to the tip ribs.

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Riveted the elevator horns to the spars.

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Bruins vs. Blackhawks in the winter classic on tv… taking a break to watch a little hockey.

Today’s Time (hours): 2.5
Empennage Time (hours): 106.0
Total Time (hours): 106.0

 

More Work on Elevators

Jared Solomon and Wes Greer stopped by today and helped move the elevators along. I really appreciate having experienced builders helping me out.  Things went really fast and their advice is incredibly valuable. Had lot’s of fun building together, too. Thanks guys!

Today we final drilled the tip ribs to one another and to the counterweight skins. We cut the foam trailing edge and trim tab ribs. We trimmed and deburred the trim tab skins. We trimmed the right elevator aft spar. We bent the closeout tabs on the left elevator skin. We fit and drilled the trim tab hinge. We clecoed everything together and fit/trimmed the elevator trailing edges.

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Jared and Wes went home and I continued building. Not even ten minutes unsupervised and I screwed up! I misunderstood the interface between the trailing edge extrusion and the elevator wing tip. I removed way too much material from the trailing edge. I didn’t realize that the wing tip would be trimmed and butt up against the trailing edge. Had I read forward to the “Empennage Fairings” section, I would have understood how this went together. Oh well… Ordered a new trailing edge from Van’s.

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Today’s Time (hours): 5.0
Empennage Time (hours): 85.0
Total Time (hours): 85.0

 

Primed and Assembled Horizontal Stabilizer

Scuffed and primed the skins, ribs, stringers and center web.

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Riveted together the inboard ribs, web, and stringers.

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Clecoed and riveted the ribs to the front spar

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Clecoed and riveted four nose ribs to the skins. Special thanks to Jared Solomon for lending me his HS cradles. Also for the awesome flight flight yesterday in his RV-14. Makes me want to build faster.

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Clecoed the forward spar and associated substructure to the skins. Ready for final riveting. Should have the HS buttoned up tomorrow!

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A very satisfying day of progress!

Today’s Time (hours): 5.0
Empennage Time (hours): 69.0
Total Time (hours): 69.0