Dimpled left top wing skins

Removed material from the corners where they overlap and butt up against the tank skin so that they’ll lay flat. I used 60 grit sand paper. Then deburred all the edges of the skins and wing walk doublers. I deburred all the holes I drilled in the doublers too.

img_2391

 

Dimpled the skins with the DRDT-2.

img_2393

 

Made it through both left wing skins before my arm got tired.

img_2394

img_2392

 

Today’s Time (hours): 2.0
Wing Time (hours): 73.0
Total Time (hours): 284.0

Much progress on rear spar

Peeled the vinyl from all the parts. Did the minor cutting and fabrication called out in the plans. Cleaned up and deburred all the edges with file, deburring tool, scotch brite wheel, and sandpaper. Scuffed everything with a scotch brite pad.

img_2298

 

Assembled and final drilled the aileron hinges. The inboard hinges are from the service bulletin. I’m surprised they haven’t updated the plans yet. Had to follow the SB instructions.

img_2299

img_2304

 

Clamped the spar doublers to the spars and match drilled them.

 

Drilled out the aileron pushrod hole in the inboard doublers and cleaned them up with the Dremel.

 

Clecoed the right rear spar together with the wing assembly.

img_2315

 

Today’s Time (hours): 4.5
Wing Time (hours): 59.0
Total Time (hours): 270.0

Work on the ribs continues

Netflix and scuff! Sophie deburred and scuffed all the ribs while I was traveling this week. Awesome job!

img_2252

I fluted and straightened all the ribs.

img_2261

I assembled and final drilled #30 the torque tube bracket assemblies.

img_2256

I clecoed the torque tube bracket assemblies to the inboard-most ribs and final drilled them to the rib webs.

img_2257

I clecoed the flap brackets and flap bracket ribs to the inboard and outboard wing ribs and natch drilled all the #30 holes.

img_2260

 

Today’s Time (hours): 10.0
Wing Time (hours): 34.5
Total Time (hours): 245.5

 

Attach bottom rudder fairing

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

img_2127

This morning, I trimmed and sanded the edges.

img_2128

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

img_2130

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.

img_2131

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

img_2132

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

img_2133

I dimpled the nut plates.

img_2134

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

img_2135

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.

img_2136

I machine countersunk the fiberglass for #6 screws.

img_2137

Everything went together just fine.

img_2138

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.

img_2141

 

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

 

Sanded and attached horizontal stabilizer tips

Sanded and fit the HS tip to fit. Before I paint the airplane, these will need to be filled and finish sanded.

img_2085

Final drilled #30, dimpled the skins, and machine countersunk the tip.

img_2090

I picked up a pneumatic rivet puller at Harbor Freight yesterday. I used it to set the rivets and attach the tips.  So much nicer the the manual puller!

img_2087

This completes the work on the horizontal stabilizer and elevators. So I’ve moved them to a safe place until I’m ready to final attach them at the end of the build.

Today’s Time (hours): 1.5
Empennage Time (hours): 205.0
Total Time (hours): 205.0

 

Attached left elevator tip

I final drilled #30 the elevator skin to the tip. Then I removed the tip and countersunk the holes.

img_2068

I dimpled the holes in the elevator.

img_2069

I had to remove the counterweight to dimple the forward two holes. Then reinstalled and re-torqued the nuts.

img_2070

Installed the tip with CS4 pop rivets. I’m thinking I might replace my pop rivet tool. I’m getting a burr on the top of all of the rivets and I’ve had several break off in the tool. I’m careful to keep the tool perpendicular to the work but this keeps happening. A while back, a mandrel got jammed in the tool. I disassembled it to remove the mandrel and reassembled it. But I think the jaws are not grabbing properly now.

img_2072

In other news, you can see that after trimming and sanding the left HS tip, it fits nicely. The right tip is another story. I think I neglected to final fit it after I sanded the foam or perhaps I seated the foam too deeply. In any event, it spread the tip about an eighth too far and now the tip wont fit between the top and bottom skins at the spar. I’ll noodle on how I might salvage the part for a while and If I can’t I’ll order a new one. My best thought at this point is to take a 1/8″ wedge out of the middle of the foam/fiberglass with a saw and then put  another layer of glass over it.

 

Today’s Time (hours): 1.0
Empennage Time (hours): 201.0
Total Time (hours): 201.0