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.

img_2736

 

Today’s Time (hours): 6.0
Wing Time (hours): 166.0
Total Time (hours): 377.0

 

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.

IMG_2681

 

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.

IMG_2683

 

Assembled the flap substructures.

IMG_2684

 

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.

img_2693

 

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

img_2692

Disassembled everything.

img_2694

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

 

 

So F’ing Close!

I thought for sure I would finish the elevators today. But no! Came up short by five AD-41-ABS pop rivets.

IMG_1847

Started the day by riveting the trailing edges. I lightly set all the rivets with the pneumatic squeezer first. Then propped everything up so that the trailing edge rested flush to the back rivet place and very carefully used a mushroom set on the bottom to finish the double flush rivets. With he “backward” trailing edge of the elevators, I almost needed to use just the edge of the rivet set. It was tricky but I’m happy with the result.

IMG_1842

Remy helped me roll and rivet the leading edges.

IMG_1844IMG_1845

I cut and installed the lead counterweights. Is it me or does installing lead in an airplane just seem wrong? 🙂

IMG_1846

And here they are. My almost completed elevators!

IMG_1848

TODO:

  1. Finish riveting the leading edge (ordering rivets today)
  2. Terminate the wires from the (waiting for crimper to arrive)
  3. safety wire trim tab hinge pin (waiting for safety wire to arrive)
Today’s Time (hours): 6.0
Empennage Time (hours): 125.5
Total Time (hours): 125.5

 

Did the Nasty

Decided to just get this out of the way tonight…

IMG_1836

I went through three changes of gloves and still managed to get it on my hands.

Prepped the scuffed surfaces with isopropyl.

IMG_1835

Sealed the trialing edge ribs in place. Peeled the tape and stuck the top skins to the trailing edges. Weighted down the aft section to ensure good bond of the skins to the ribs. The sealer cures in six hours according to the data sheet. So should be riveting the trailing edge and finishing up tomorrow.

IMG_1837

Bent the trim tab hinge pin per the plans.

IMG_1838

 

Today’s Time (hours): 1.0
Empennage Time (hours): 119.5
Total Time (hours): 119.5

 

New Trailing Edge and Skin Prep

I got home from a grocery run with the family and my replacement trailing edge was waiting in the driveway. Thank you, Van’s. Their shipping team is not taking any chances. The trailing edge was wrapped in paper, and sealed in a length of PVC pipe with PVC end caps. The end caps were sealed with that tape they use for packing everything. This is the stickiest tape ever. I’m thinking I might build a plane from it after the RV is done.

IMG_1800

IMG_1801

I was just going to bring it down to the shop. But once I saw the packing job, I just had to open it.  …and since I was down there and the drill press was still set up for countersinking trailing edge, I clecoed it to the skin, marked it, trimmed it, and finished the outboard end correctly this time. And then I countersunk it.

…and while I’m down here, I might as well prep the skins for bonding, too. Same drill as the trim tab… Measure, tape, strip primer with isopropyl, sand, and wipe with acetone.

IMG_1802

Ready to start assembling the elevators!

Happy New Year!

Today’s Time (hours): 2.0
Empennage Time (hours): 103.5
Total Time (hours): 103.5

 

Rudder Completed!

I riveted the trailing edge this morning. The double flush riveting was actually pretty straight forward. The edge turned out pretty straight and didn’t require much fiddling.

img_1660

Later, I rolled the leading edges. Then clecoed and blind riveted them to complete the rudder.

img_1666

Today’s Time (hours): 5.0
Empennage Time (hours): 41.0
Total Time (hours): 41.0

 

Riveted everything together

I finished back riveting the stiffeners to the skins. I had one oops where a rivet got cockeyed just before I drove it. It left a ding in the skin but didn’t penetrate. I debated replacing the skin but opted to move on.

I used 3M F9460PC double stick VHB tape to secure the trailing edge extrusion to the skin and clecoed it together. I put some long rivets through every tenth hole or so, put the tape on both sides of the wedge, and used the rivets to properly register the taped wedge to the right skin. Then I clecoed it in place and removed the rivets.

I riveted the stiffeners and shear clips together. I removed the backing from the other side of the tape while I pried the skins slightly apart so the strip didn’t tear. I removed clecos as I worked my way to the top of the trailing edge. I pressed the left skin into the tape and clecoed every hole.

I mounted the counterbalance. I had to file a bit off of the forward corners to clear the shop heads of the rivets holding the counterbalance rib in place. I riveted the skin to the spar, and riveted everything else except the trailing edge. That will be tomorrow’s adventure.

I neglected to shoot progress photos along the way but here’s the result of today’s work…

img_1656

This is the tape I used…

img_1658

Today’s Time (hours): 6.0
Empennage Time (hours): 36.0
Total Time (hours): 36.0