Started work on the ailerons

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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

 

Fitting the flaps together

Assembled the inboard and outboard rod end ribs. Clecoed the ribs and doubles together. Match drilled the #40 holes and final drilled the 1/4″ hole. Countersunk the #40 holes on the outboard doublers.

 

Clecoed the ribs to the flap hinges and final drilled all the #30 holes.

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Modified all the main ribs by removing the top forward tab from each with the Dremel and a cutoff wheel. Finished with a bit of sanding to remove the burrs.

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Assembled the flap substructures.

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Trimmed the inboard and outboard trailing edges to final size with the bandsaw and finished on the scotch brite wheel.

 

Clecoed the flaps together.

 

Match drilled the two top holes in each of the nose ribs. I also final drilled all of the holes in the trailing edges.

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Assembled the hardware in the hinge to hold everything in alignment and match drilled the four holes in the  trailing edge of the hinge.

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Disassembled everything.

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Next I need to machine countersink the holes in the trailing edge wedge and the holes I just drilled in the hinges. Then dimple and prime everything.

Today’s Time (hours): 6.5
Wing Time (hours): 152.5
Total Time (hours): 363.5

 

 

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

 

 

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

 

 

 

Prepared tank stiffeners

Dimpled the nut plate attach holes in the inboard tank ribs.

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Separated the stiffeners.

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Used snips to make all the cuts. Doh! Should have peeled the blue vinyl off before I cut them.

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Then cleaned them up on the scotch bright wheel, scuffed the mating surfaces and dimpled.

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Today’s Time (hours): 2.0
Wing Time (hours): 127.0
Total Time (hours): 338.0

 

 

 

Work continues on outboard leading edges

Deburred all the edges of all the things. The doublers for the landing light lenses looked like they were crafted by Van’s with a chainsaw. You can see the before and after shot below. I used sandpaper to work the flanges around the nose of the ribs so that the skins don’t telegraph any faceting.

Trimmed the four ribs called out in the plans so that they will fit around the spar braces. Finished with files and sandpaper.

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Flattened, straightened and fluted all the ribs. Then final drilled and deburred all the holes.

Dimpled all the holes with the squeezer.

Cut the J-channel stiffeners to length and drilled the first inboard hole in each.

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Final drilled #19 the screw holes in the splice strips. Carefully deburred the holes and dimpled for #8 screws. Dimpled all the #40 holes as well.

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In other news, I received the order confirmation for the engine I ordered at Sun ‘n Fun. The ship date from Lycoming is October 11.

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Today’s Time (hours): 5.0
Wing Time (hours): 94.0
Total Time (hours): 305.0

Fixed the right aileron hinge and riveted to rear spar

Did some flying with Jared today in his RV-14A. Awesome day dancing around some scattered clouds and some fun aerobatics. Thanks for the great flight today, Jared! The aerobatic training is definitely paying off. Sorry no pics. I was having too much fun!

Meanwhile back at the airplane factory…

Received the replacement parts from vans and did the little bit of fabrication necessary to prepare the doublers and attach brackets.

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Deburred and primed the new parts with SEM rattle can primer. Riveted the attach brackets to the hinge.

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Riveted the hinge and doublers to the right rear spar.

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The mistake cost me $45 in parts and an hour and a half of build time.

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Got my new 3/8″ reamer from McMaster Carr. Used it in the drill press to precisely size the rear spar attach holes. The twisted flutes cut like butter.

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Clecoed the rear spars to the wing ribs. Ready to rivet tomorrow.

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Today’s Time (hours): 2.0
Wing Time (hours): 67.0
Total Time (hours): 278.0