Friday, November 29, 2013

Flaps! -- Section 19 Completed

Build Hours Added Since Last Post: 28.0

Section 19 is now complete.  It took, what seemed like, a long time.  It's a great feeling to watch the mountain of parts form the wing kit slowly deplete to just a few remainders now.  At this point, the pieces for the ailerons are the bulk of the remaining parts.  If a lack of parts were my concern, the good news is that the empennage and tailcone are coming my way.

Dimpling the flap skins
Parts are all primed and the left flap is ready for rivets
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The left flap is affixed to the wing

Both flaps are mounted

A well-deserved beer after a long day of plane building
Next up, the ailerons!

Monday, November 18, 2013

Flaps! Section 19

Build Hours Added Since Last Post:  16.75

With the bottom wing skins affixed and the main structures of the wings effectively completed, it's time to move onto the control surfaces.  Section 19 (which has now been changed to Section 21 in the revised plans) sets forth the construction of the flaps.  There's nothing particularly interesting to say about the build process of the flaps, but it's vitally important that they be built straight and true.  This effectively means that the trailing edges of the flaps and ailerons be as linear as possible with little to no warping.  In my practice kit (whereby the kit is essentially a segment of the flaps), I was able to rivet a straight and true trailing edge.  Hopefully, that wasn't simply beginner's luck and I'll be able to replicate it here without much trouble.

Prep, prep, prep...

Here are the bones of the flaps all clecoed together.

Yet another run to the tool shop.  A couple more tools acquired.

Here's what the flaps will look like when they're all finished.  But for the time being, it's all temporary.

Next up, I need to dimple the components and skins, countersink the brackets, and prime all of the internal parts.  After that, I'll be that much closer to getting the flaps finished and it will be onto the ailerons.

Sunday, November 10, 2013

Section 18 -- the Bottom Wing Skins -- Completed!

Build Hours Added Since Last Post:12.0

After what seemed like an eternity, the bottom wing skins on the left AND right wings are fixed in place and Section 18 is done!  This means that the main wings are effectively finished.  Now, I know what you're saying.  But what about the flaps, ailerons, wingtips, and actuation controls.  Ok, those things have yet to be done, but the main wing structures are done.

It's important to sign your work.

Whew!  Onto the flaps!!

Saturday, November 2, 2013

Section 18 Continues -- The Bottom Wing Skins

Build Hours Added Since Last Post: 11.0

Work continues on the bottom wing skins.  After finishing up the dimpling and priming of the skins, they were ready for installation. 

I started by placing the shorter inboard skin and riveting it to the rear spar.  The tricky part about affixing the bottom skins is that there is no easy access to the inside.  So it's a bit of contortion-ism to get the bucking bar on the backside of each rivet.  So in order to make my life a little easier, I invested in a tungsten bucking bar.  And let me tell you, its worth every penny.  It's dimensions are roughly 1" by 5/8" by 4" and it weights 1.65 pounds.  For reference, that same size bar made from gold would weigh roughly the same amount. 

After the skin is riveted to the rear spar, I worked my way forward--stopping just after the J-channel support that runs the span of the wing.

Once the skins are riveted to the mid-point, I then continued working forward (or down from this perspective).

Before I knew it, the skins were riveted to the left wing!

Then I mounted the pitot tube and the three inspection plates.

Now I get to do it all over again on the right side.  With any luck, it will go a bit quicker since there's no pitot tube or ADHRS to mount on that side.