Last post of 2010

Leading edge added

Nut plates along the perimeter of the access hole

A fuel tank bracket

Continuing to make and install the tank brackets

Tank ribs added inboard on the main spar

Adding the tank skin

Cleco madness

A template to transfer the outline of the inboard tank rib to the aluminum that will be used for the tank mount to fuselage

Top skins, leading edge and fuel tank clecoed on to the spars

but not the bottom skins yet

Happy Holidays

We had a wonderful Christmas.  After the morning celebration, I had the rare opportunity of a day off work with few responsibilities.  I was able to put about four hours of work in to the left wing.  Mike just recently made it home from the UK (he got caught in the snow related closure at Heathrow), so Doug and Mike enjoyed each other's company today, which is as it should be.   I worked out in the garage by myself.

Countersunk nut plates riveted to the reinforcing plate

Figuring out the orientation

Installed on the left wing

The skins are large and somewhat flimsy.  I find a roller stand of adjustable height to be very helpful

The dimpling table

Top skins clecoed on and leading edge assembly in place

Rivet banging-Easier with two

Doug is able to get his hands in to tighter spaces than I am.  I know this can be done solo, but boy, it's an easier job to buck rivets with two people...

Riveting the ribs in the wing walk area

The ribs in this area are very closely spaced

Why building an airplane takes so long (part one)

 The ribs used in the wing come already cut and formed, and with small holes for the rivets in the flanges and large holes in the main surface (the"web") drilled to lighten them.  So assembly should just be as simple as lining them up with the spar, and riveting away.  Well, not exactly...

First, the ribs have to be "prepped".  This consists of hitting the edges with a Scotch Brite wheel to round off any burrs from the cut edges, then bending the edges to a perfect 90 degrees with a hand seamer, then
rounding off the interior edges with a Dremel, then drilling holes for the wiring to pass through, then using a Scotch brite pad by hand to scuff all of the surfaces, then dimpling the rivet holes, then fluting the flanges to straighten the rib, then degreasing and cleaning the ribs, drying them and finally, priming then with a self etching metal primer.  And there are over fifty of them.  So the past few days, in my builder's log, it just keeps saying "prepped ribs".  That's why.

My makeshift painting booth and HVLP for the primer

I recycled the shipping box as a painting table

        

Primer sprayed

Prepping the ribs

Experimental aircraft builders know that the FAA will require proof that we actually did the work.  While I am not the most photogenic guy, Doug is happy to snap a few photos to prove "I was there" (but he usually sneaks off to get a few photos with a more interesting composition- see below)

The left leading edge, showing off the cradle

Reflections inside the leading edge

"Fluting" to make the rib align straight

"Dimpling" to allow the skin and rib to interlock, and the flush rivets to be flush

More of Doug's eye for the interesting

Some progress on the left wing

Rear spar doubling plates.  The blue tape is to keep me from putting rivets where they aren't supposed to be (yet).

The "shop".  Formerly the third bay of the garage.

Starting to look "wing-like"

I love Doug's eye for details like this.  A view down the lightening holes in the ribs

I spent some time finishing the frame the wing hangs in while the internal bracing is completed.  Doug and I finished the rear spar, and would have finished the main spar, except we broke all three of our #40 pilot 3/32 countersink cutting drills.  Oh well.  At least we can proceed with prepping the ribs and priming them this weekend.  I let Doug do the photography this time.  I think he does a better job (see second to last photo, above)

The wings are here!!!

One of two boxes, opened to inventory

Doug begins machine countersinking the main spar for the attach plates

Using the "main squeeze" to set rivets

Modeling the Embry Riddle hoodie he got from our friend Ryan

A view down the main spar at the attach plates, riveted

Fabricating the tie-down assembly

Trimmed the rear spar doubler plate

I drove up to Aurora, Oregon, to Van's Aircraft, and picked up my wing kit on Wednesday.  I didn't get a chance to do much until this weekend, but here are a few shots of the progress.  Thanks to my friends, Tom and Ryan for helping me unload the kit out of the truck.  Over 300 pounds for each of the two crates.  I could not have done that by myself.