Final drilled ribs to spars and drilled systems holes.

Spent a lot of time finishing the deburring of all the holes in the flanges and finishing dimpling the lower flanges of the ribs.

Clecoed the ribs to the spars and final drilled all the holes in the forward flanges.

img_2273

Disassembled everything  and deburred the rest of the holes.

Measured, marked, and drilled the systems holes with the step drill.

Deburred all the the systems holes.

Ready to prime and assemble ribs.

Today’s Time (hours): 7.0
Wing Time (hours): 45.5
Total Time (hours): 256.5

 

Started attachment of elevators to horizontal stabilizer

Screwed the rod end bearings into the elevator forward spar.

img_2028

Fitting the right side was very tight. I’m sure theres a proper tool to do this but I ended up using a cresent wrench to twist the bearings. There was no way I could do it by hand.

img_2027

On the left side I couldn’t even get the threads to engage. On close inspection I discovered that the nut plates were a hair off center from the hole in the spar and reinforcement plate.  I enlarged the hole by a 16th being careful not to damage the nut plate. Then I  was able to get them screwed in with the cresent wrench. I screwed them in to the measurement called out in the plans.

57083714467__846fca30-fec6-4337-930e-493c67b1bf7e

I temporarily attached the left elevator to the horizontal stabilizer. I checked the clearance of the forward edge at the maximal up and down deflections. I used a digital level to fin the maximal deflection points. I had remove the elevator and backed the rod end bearings out three turns to get the necessary clearance.

img_2030

I used a clamp to lightly hold the elevator in the trailing position to locate the pivot hole in the elevator horn.

img_2031

I made a spacing block as called for in the plans and clamped it in place. I then honed down the drill bushing to get a snug fit in the bearing and used it to drill a #30 hole in the elevator.

img_2032

img_2033

I enlarged the hole hole to 1/4″ with a step drill and deburred the hole. Then repeated this whole process on the right elevator.

img_2034

I reattached both elevators to the horizontal stabilizer. I used the appropriate hardware to make up the center hinge. It was extremely challenging getting the washers between the horns and the edges of the bearing. I ended up taping the washers to a small piece of scrap aluminum and using it to shoehorn the washers in place. Then I lightly clamped both elevators into the trailing position.

img_2035

I measured and marked the location for the control attach hole on the right elevator and drilled a #40 hole and final drilled it to #12.

img_2036

Tomorrow I’ll make a guide block and match drill the hole to the other horn.

Today’s Time (hours): 3.0
Empennage Time (hours): 189.0
Total Time (hours): 189.0

 

More work on bulkheads

Modified the bottom of the 1408 bulkhead.

IMG_1893

Deburred and dimpled all the 1407 and 1408 bulkhead parts.

IMG_1895

Separated, deburred, and dimpled the bell crank ribs.

IMG_1896

I realized when I went to drill the battery angles that I somehow modified the wrong one. I could swear that I marked these parts carefully before I separated them but it appears I switched the A and B markings. I don’t think this will be a problem though. I just needed to modify the correct one. The modification to the wrong one is not consequential.

IMG_1897

Once I fixed that, I drilled and countersunk all the nut plate holes and match drilled the angles to the bell crank ribs. I deburred and dimpled the 1406 bulkhead as well.

IMG_1898

I think next weekend I’m going to have two solid days of scuffing and priming all these parts.

 

Today’s Time (hours): 4.0
Empennage Time (hours): 141.0
Total Time (hours): 141.0