Saturday November 1, 2008: Flaperon Actuation & Pivot Brackets

Wings complete and now on to the flaperons! Don't let the long interlude fool you, I spent time in between 10/18 and 11/1 working on page 18-02 getting the actuation bracket (A1207-L & R) and the pivot bracket (A1206) correctly manufactured. I had to make a visit to Van's to pick up additional AA6-125x1.5x2x10 because of my lack of precision in placing the pivot hole. Now, I don't know if I was being too much of a perfectionist or not, but I didn't want to be flying at 6,000 ABG and wonder if the flaperon was correctly manufactured/assembled.

So, I have 2 sets of actuation brackets, one of which is a better fit. The pivot brackets went well. I followed the example of Marty Santic (http://martysrv12.blogspot.com/2008/09/continuing-with-flaperon.html) who had consulted Jim Cone, etc. (It's a builder's community!) Using the drill press I enlarged the hole as per diagram directions on 18-02, step 2, and then while still in the drill press, put the tap into the press and rotated by hand to ensure that it went in straight. After a number of rotations, I removed the bracket and completed tapping with the bracket in the vice. This worked quite well. All parts then deburred and primed using the Napa 7220 rattle can.

Saturday, October 18, 2008: Wing tip close-out

Tim and Tiffany came over and after I made them breakfast, Tim and I worked on the final stage of right wing tip. Everything went together well and the trailing edge of the wing tip was parallel to the wing. The only problem was that I read and re-read the plans so many times that I didn't pay close attention the final time and used the #3 rivet instead of the #4 as called out. I may go back and drill out the 6 rivets this covers and replace. I think it would make for a tighter fit.

Friday, October 17, 2008: Completed Wing tip close-out

Deburred Wing tip close-out skin and then bent tabs following the directions (17-06). I used a protractor and it worked pretty well. I cleoed the close-out onto the wing, and needed to take if off once to readjust a couple of the tabs, although minor. When finished and cleoed into place, it was a good fit and went on to rivet in place. The deburred and cleoed the wing tip trailing edge into place. What I don't quite figure is why check for parallel when the cleoed holes pretty much dictate placement with little if any latitude in movement. Oh well, will follow directions precisely and finish it up. Son Tim is coming for breakfast, with his girl friend Tiffany and after breakfast I'll get him to help me flip the wing and check for parallel. Then we'll finish the wing and put it into the cradle.

Thursday, October 16, 2008

Tonight, I worked on the handhold, riveting into place along with rib and wing skin. I did need to trim the rear spar assembly to accept the flanges (17-05). I think the trim job I did was find, but upon closer examination, one would not have to trim too much to make things fit. Wing tip ribs in place clecoed then riveted. Tomorrow I'll tackle the wing tip close out.

Van's notified me that the fuselage kit would be ready for me to pick up the week of November 4.

Wednesday, October 15, 2008: Wing walk doubler installed

The debacle wasn't so bad after all. I visited Vans and bought a new doubler, but before I pulled the plastic off, decided to try one more technique to bend the edge, which was wavy by this time. Using the hand seamer, I bent the edge and darned if it didn't work! It took the waves out and made the bend. So proceeded to clecoe in place and rivet. I did not have to strap the doubler down like Jim Cone did, but I suspect he has a much snugger fit along the edge.

So, I'll return the extra doubler to Van's when I pick up the fuselage kit which I was told would be ready the week of November 4. WooHoo!

After the doubler installation, I moved on to the wing tip hand hold, rib and wing skin. Everything clecoed into place, but not riveted. I'm in a one-car condo remember and I can't make too much noice or my very understanding neighbors could become grouchy. I'm lucky to have such good neighbors so I like to be careful not to take advantage.

October 10, 2008 Right Wing Skins Install, Wing Walk Doubler Debacle

Attached top wing skins and riveted in place. Began work on wing walk doubler. I tried using the edge rolling tool but the result was wavy without the intended bend. Frustrating to say the least. I'll leave it for today and see if I can remove the waves tomorrow and get a bend with the tool. If not, I'll have to purchase another wing doubler skin and try again.

October 7, 2008: Right Wing Top Skin

Visit from EAA tech councilor very helpful with good advice. Deburred top wing skins using file, deburring tool and sand paper. Very good combination and satisfied with finish. Cleoed top skins all on and will rivet next opportunity I get to spend time on plane.