Aileron assembly continues

Dimpled the leading and trailing edge holes in the top and bottom skins as well as the holes in the main ribs attached to them. Dimpled all the holes in the leading edge skins as well as the spars.

Machine countersunk the trailing edges.

Riveted the skins to the nose ribs.

Blind riveted the spars to the nose ribs.

Riveted the top and bottom skins to the nose assembly of the left aileron. Riveted the top and bottom ribs together. Riveted the nose skin to the counterbalance.

Prepared the left trailing edge by wiping it down the alcohol and applied the VHB tape to both sides. Then set it in place in the aileron and weighted everything down while resting the edge on a piece of angle iron. I remove the top backing tape by working my way across the aileron by removing a handful of clecos peeling the tape then replacing them with the next handful of clecos down the line until the whole backing tape was removed. I let the tape set up for a while and repeated the process for the bottom.

While the VHB tape sets up on the left aileron, I got started on assembling and riveting the right aileron. Got as far as riveting the top skin in place.

Today’s Time (hours):	6.0
Wing Time (hours):	185.5
Total Time (hours):	397.5

Dimpled all the ribs and stiffeners

Got my rivet set and AD5 rivets from spruce and replaced the rivets I removed after screwing up last week. See Finished riveting everything to the rear spars… almost.

Dimpled all the ribs in both wings…

…and the J-channel stiffeners

Today’s Time (hours):	1.5
Wing Time (hours):	75.5
Total Time (hours):	286.5

Riveted rear spars to ribs

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.

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.

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

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.

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

Riveted the hinge and doublers to the right rear spar.

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

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.

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

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

Primed and started riveting the rear spar and Ordered Engine and Prop

Had an awesome time at Sun N Fun with Jared, Wes, and the Family. That’s me ordering an engine and prop in Van’s tent! And that’s me and Remy sitting in the RV14 at Van’s booth. Suddenly this is getting more real.

We got back from Lakeland this morning and I got right back to work. No rest for the wicked! Primed the rear spars and all of their associated parts.

Clecoed the aileron hinges together.

…and riveted them.

Clecoed the spars together.

Started riveting the doublers to the spars with the squeezer.

Today’s Time (hours):	3.0
Wing Time (hours):	63.0
Total Time (hours):	274.0

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.

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

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

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

Rinse, repeat, right spar complete

Match drilled the J channel to the spar.

Machine countersunk the nutplate attach holes.

Riveted in the nutplates

Countersunk the screw holes.

Machine countersunk all the skin attach holes.

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

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

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

Installed and torqued the aileron bell crank brackets.

Right spar done!

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.

Final drilled and deburred the left aileron brackets.

Scuffed and primed the aileron brackets with rattle can.

Installed and torqued the aileron brackets to the spar.

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

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

Started the wing build

Screen Shot 2019-05-27 at 10.10.58 AM

Cut the J channel to the specified lengths with the Dremel tool and a cutoff wheel.

Clamped the J channel to flange leaving it 1/16″ proud of the flange.

Drilled and clecoed the J channel.

Flipped the lower J channel to the upper flange to finish the holes where the nut plates were on the lower flange. I marked the J channel and set aside for later when the skins go on.