Tuesday, September 3, 2019

16 - Top Wing Skins (finished); 17 - Outboard Leading Edge (finished); 18 - Fuel Tank (attached to wing); 22 - Ailerons (started fabricating, up until stiffeners)

I haven't posted in ~2 weeks, because of a little trip to NYC to watch the US Open and eat at a few restaurants that only NYC can provide.  We just beat Dorian, which is now a Cat 2 hurricane and likely to miss our house.  In honor of Dorian, I worked over 6 hrs in the shop today, as well as a bunch the days prior to our vacation on a total of 4 sections:

- riveted skin to all ribs, mounting bracket, splice strip and j-channel; drilled 3/8" hole for tie-down
separated, deburred hinge brackets; deburred, buffed, and dimpled nose rib flanges; countersunk and riveted hinge brackets to nose ribs; riveted nutplates to nose ribs
- separated, deburred, dimpled and riveted main ribs to hinge brackets; deburred spar and nose skin edges; clecoed nose ribs to spar and nose skin; match-drilled 6 holes in the stainless steel counterweight.  THAT by itself took well over 2 hrs, a lot of swearing, some boelube and water as lubricants, and a broken drill bit
- match-drilled #40 the remaining 8 holes in leading edge to SS counterweight; final-drilled #30 all 10 leading-edge holes to SS counterweight; final-drilled #40 holes in skin stiffeners
- Riveted right top skins to 4 ribs, skin overlap, and main spar (my wife used back-riveting bucking bar)
- Riveted top skins to rear spar
- riveted outboard aileron to spar and outboard rib; riveted inboard rib to skin and nutplates
- cut and deburred 32 aileron ribs (for both sides)
- riveted j-channels with my wife; top wing skins done
- attached leading edge skins to right spar (my wife helped buck the top flange); blind-riveted ribs to spar;
- attached right fuel tank to right wing … all nuts final-torqued and screws; except for ONE screw, b/c Van's provided me a nutplate that has no threads - time to order a tapping toolkit and tapping fluid

Riveted the last parts of the right outboard leading edge:



Another view:


Outboard edge:


Riveted j-stiffener to right outboard leading edge:


Right outboard leading edge, completed:


Final drilled tiedown hole:


Started ailerons, both sides:


View of aileron nose ribs:


Aileron inboard and outboard ribs, both sides:


Left aileron counterweight - that stainless steel is a pain in the ass to drill!


Leading edge of left aileron match-drilled to counterweight:


Pink Boelube paste works well for drilling stainless:


Right wing, top skins, partially back-riveted thanks to my wife:


Another view:


Trailing edge of top skins, squeeze-riveted:


Inboard rib, riveted with squeezer:


Outboard aileron hinge bracket attached to rear spar and outboard rib:


32 aileron stiffeners, fabricated:


Top skins (right wing), fully riveted:


Another view:


Blind-riveting the outboard leading edge to the right main spar:


Another view:


Top part of outboard leading edge (on bottom here) riveted to main spar flange:


Finished riveting right outboard leading edge:


Another view:


Fuel tank, attached with screws and bolts (final-torqued):


And thanks a lot, Van's, for providing a nutplate with NO threads (I'll have to tap this once my tapping tool kit arrives):


Leading edge and fuel tank, attached:




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