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.

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Riveted the skins to the nose ribs.

 

Blind riveted the spars to the nose ribs.

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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

 

Primed everything and started assembly

Primed all the aileron parts.

 

Riveted the various hinges and doublers to the various ribs.

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Clecoed the nose ribs to the spars and set in the skins with the stainless counterbalance tubes. Match drilled the inboard and outboard holes from the leading edge of the skins to the counterbalance.

 

Today’s Time (hours): 4.0
Wing Time (hours): 175.0
Total Time (hours): 387.0

 

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

 

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

 

Primed everything and began assembly

Primed everything

 

Riveted the nutplates and doublers to the rod end ribs.

 

Riveted the hinge halves to the ribs. Then installed the hardware and double flush riveted the halves together.

 

Today’s Time (hours): 2.0
Wing Time (hours): 158.0
Total Time (hours): 369.0