Monday, August 19, 2019

16 - Top Wing Skins (right side riveting started); 17 - Outboard Leading Edge (right side, riveted top skin-to-ribs); 21 - Flaps (Finished right flap)

It is amazing how a major deadline (pending fuselage kit delivery in a few weeks!) can help me focus and knock out tasks on multiple projects.  Lots of small but important tasks were accomplished this past week, in just about every available minute.  The kids and wife saw very little of me, because I completed the following:

- countersunk holes in right rear wing spar corresponding to doublers; deburred edges and holes; shaved wing skin mating areas on forward part of outboard and inboard skins; dimpled all holes in inboard and outboard top skins; primed shaved skin mating areas; clecoed wing walk doublers and inboard and outboard top skins to wing assembly; deburred & dimpled j-stiffeners
- Left and Right flaps: attached trailing edge with 3M VHB tape; clecoed trailing edge and ribs; riveted trailing edge (squeezed); riveted bottom skin to ribs; attached flap to wing (temporary, left side only)
- right leading edge:  7 leading-edge ribs: straightened flanges, fluted flanges, deburred edges and tips, final-drilled #40 and #30 holes; deburred holes in 7 leading-edge ribs; dimpled flange holes; deburred, final drilled and dimpled splice strip; clecoed 7 ribs into the leading edge skin; match-drilled, deburred, dimpled j-stiffener
- Riveted right top skins to 9 ribs (200 rivets, with wife using back-bucking bar)
- Dimpled right leading edge skin; masked and scuffed area for black matte paint (light well/bay)
scuffed, cleaned and primed 7 ribs, mounting bracket for landing light, and mounting wedges for light lens, and skin; primed and painted black all areas visible in landing light bay; riveted nutplates to splice strips, mounting bracket and mounting wedges. Note that Van's doesn't supply enough K1100-08D nutplates, but way too many K1100-08 nutplates ... I guess I just have to dimple the #40 holes in the latter (which I did, and which were not a big issue).
- clecoed 7 ribs and splice strip to leading edge skin (right); riveted all top rivets and aft 3-most bottom rivets on all ribs

Primed shaved skins on inboard top skins (forward overlapped parts):



Outboard skin, primed:


Dimpled outboard skin:


Dimpled inboard skin:


Skins clecoed to right wing assembly:


Other side.  Note that I forgot to take pics of the 9 ribs that were riveted this week - oops, I'll post it next week:


VHB-taped and clecoed left flap, waiting to be riveted using special safety-pin squeezer set from Cleaveland Tool:


Trailing edge riveted:


Left flap completed:


Left flap temporarily installed on left wing:


Another view:


Third view:


Right flap, completed:


Another view:


Closeup, with my ugly mug for the FAA:


I forgot to take pictures of a bunch of steps for the right leading edge (i.e., all the work to prepare the ribs for this step).  Here are the 7 ribs clecoed to the skin, as well as the j-channel, ready to be match-drilled:


J-channel, matched drilled:


Ah, here are the ribs.  Trust me, they've been straightened, fluted, final-drilled, deburred, cut (certain ones, for clearance) and dimpled:


Dimpling the j-stiffener:


Deburred, dimpled, scuffed, primed, and black-painted the landing light mount and lens mounting bracket strips:


Since the ribs were not alclad, I primed them (just like the left side):


The two outboard-most ribs were primed and the internal surfaces were painted black, so the light bay would have a nice, black background:


Skin portion of light bay scuffed, primed and painted black:


Splice strip, deburred, dimpled, and nutplates riveted:


Nutplates riveted to light mounting bracket and light lens mounting strips:


Right leading edge skin clecoed to 7 ribs and splice strip:


Another view.  Note that the top part of the skin has been riveted and the bottom aft 3 rivets have been riveted.  More to come in the next update:




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