Nov 06, 2019     Attach angles Right Rear Spar - (6 hours)       Category: Rear spar

  Nov 05, 2019     Finished LEFT Rear spar capstrip AD4 AD5 rivets - (6 hours) Category: Rear spar

  Nov 05, 2019     Aileron Pocket Rib Locations       Category: Rear spar

  Oct 30, 2019     Right Rear Spar rivet cap strip - (8 hours) Category: Rear spar

  Oct 29, 2019     Mark do not rivet locations with blue tape - (.5 hour)       Category: Rear spar

  Nov 05, 2019     rear spar ad4 capstrip riveting - (1 hour)       Category: Rear spar

  Nov 04, 2019     rear spar ad4 capstrip riveting - (1 hour) Category: Rear spar

  Oct 31, 2019     AILERON POCKETS - (4 hours)       Category: Rear spar

  Oct 29, 2019     Rivet right rear Spar CAPSTRIPS AD4 - 6 - (8 hours)       Category: Rear spar

  Oct 29, 2019     Mark do not rivet locations with blue tape - (.5 hour) Category: Rear spar

  Oct 29, 2019     Mark do not rivet locations with blue tape - (.5 hour) Category: Rear spar

  Oct 29, 2019     Cleco and bolt cap strips on right spar - (6 hours)       Category: Rear spar

  Oct 28, 2019     Should not have done at this point       Category: Rear spar

  Oct 24, 2019     Attach Angles - (8 hours) Category: Rear spar

  Oct 24, 2019     Attach Angles - (1 hour)       Category: Rear spar

  Oct 22, 2019     Left rear Spar attach angle - (3 hours)       Category: Rear spar

Attach angles requre AD4-6.5 rivets. I use a lathe to trim AD4-7 rivets. Do not waist money on rivet cutter.

  Oct 22, 2019     Spar attach ad5 rivets all capstrip rivets done - (7 hours)       Category: Rear spar

rivet cutter are useless, since I do not have the right size rivet I use a lathe to trim off a longer rivet to make the correct size. Do not use rivet cutters. They make cuts that are not square.

  Oct 21, 2019     TP116 rivet squeezing ad4-6 RIVETS       Category: Rear spar

TP116 - Hand Rivet Squeezer
AD4-6 RIVETS CAN BE DONE IF HANDLES HAVE MORE LEVERAGE
1 1/2 inch clearance required for rear spar web flange.

Can not be used on Main Spar.
Small white copolymer washer used if rivet needs to be seated before squeezing.

  Oct 21, 2019     left rear spar more riveting - (8 hours) Category: Rear spar

  Oct 20, 2019     more riveting on left rear spar - (6 hours) Category: Rear spar

  Oct 19, 2019     Rivet - (8 hours)       Category: Rear spar

I use cleco and 3mm screws to hold capstrip while riveting.

  Oct 18, 2019     Begin riveting       Category: Rear spar

  Oct 13, 2019     Finished priming all rear spar parts and wingtips and 13 center ribs - (8 hours) Category: Rear spar

  Oct 09, 2019     Remove plastic cover on alcad remove ink - (4 hours) Category: Rear spar

  Oct 09, 2019     anodize - (4 hours)       Category: Rear spar

  Oct 08, 2019     Debur and scotch brite - (9 hours) Category: Rear spar

  Oct 04, 2019     prep for anodize capstrips - (8 hours)       Category: Rear spar

Capstrips have to have holes debured, and scotch brite. After several cleanings they are ready for the acid bath. The felt markings will not survive the acid. I have some alodine markings that should survive. Just in case I place a placed a couple of rivets to align the match drill sets (front and back). I then sand a unique pattern in the end while taking a picture allowing the set to be identified as a backup plan.

The trough for the etch alodine process was made for the Main Spar capstrips. I already had the parts but it still takes time to level the split 4 inch pipe.
One trough is water,one trough is acid,and the final trough is alodine.

There are other ways of alodining capstrips, this is just my preference.

  Oct 04, 2019     1/16 spacer - (2 hours)       Category: Rear spar

I could not find 1/2 inch strips of 1/16 6061. I purchased several lengths of 3/4 6061 angle.
Both legs of the angle can be salvaged.
6061T6 ANGLE 3/4X3/4X.062 8FT 03-00185-8 1 $19.68 $19.68 08/13/15 'www.aircraftspruce.com 6061T6 SQ & RECT

  Oct 03, 2019     rear Spar parts anodized - (1 hour)       Category: Rear spar

Ran a quick test to see if my new marking system would survive the acid- alodine. With the main spar I used a magic marker and a lot of effort to redraw ink after each process.

This is my plan for parts for the rear spar. I buff a small area - and clean with acetone - on parts that I want to mark. I paint the lettering that at this point only exist as a felt marker.

The part is then placed in the acid bath - alodine cycle. I found that the alodine markings survive the acid bath. They also are visible thru after the real alodine dip.

I try to put such a thin coat of primer on that the markings should still be visible thru the primer after drying.

ALODINE �� ALUM COND 1201-GAL 1 $44.83 $44.83 07/27/18 http://www.wicksaircraft.com
ALUMIPREP **HAZARDOUS** 33-GAL 1 $36.89 $36.89 07/27/18 http://www.wicksaircraft.com CHEMICAL

  Oct 03, 2019     prep for anodize of rear spar - (8 hours) Category: Rear spar

  Oct 02, 2019     Rear Spar ready for anodize - (8 hours)       Category: Rear spar

All holes completely match drilled. At least one of the Hinge mounting locations expanded to 3/16 per drawing. Extra material trimmed off of end of outer web.
All critical dimensions measured and verified. Made some more tooling.

  Oct 02, 2019     locations offset by 1 1/4       Category: Rear spar

  Oct 01, 2019     flap outer hinge       Category: Rear spar

  Oct 01, 2019     flap inner hinge       Category: Rear spar

  Oct 01, 2019     aileron inner hinge       Category: Rear spar

  Oct 01, 2019     outer aileron hinge       Category: Rear spar

  Oct 01, 2019     aileron hinge mount       Category: Rear spar

  Sep 30, 2019     hinge       Category: Rear spar

  Sep 30, 2019     hinge - (8 hours)       Category: Rear spar

Completed match drilling. Spar Ready for debur anodize, and prime.

  Sep 28, 2019     Match drill web and spacers. Upsize to #30 for AD4-5.5 - (8 hours) Category: Rear spar

  Sep 28, 2019     attach plate - (1 hour)       Category: Rear spar

The four pieces that made up the attach plate are already match drill (undersize #40) . The goal of this operation is to match drill the whole assembly to the web and the front and back capstrips. In general the capstrips are match drilled already. In the area under the attach plate however, there are no holes until this operation is completed.

The drilling jig is a cheap vice grip that has been cut up and attached to a floating drill bushing. The drill busing is a 1/2-13 bolt that has been center drilled with the drill size to be used. The attach plates had a #40 match drill already. The pin's tip is sized for a #40. The pin's shank is 1/8. By placing the pin in the #40 attach plate hole, and then locking pliers down, a larger concentric hole can be made thru entire assembly. I use a 1/2-13 bolt as the bushing. It can be swapped out with whatever size drill bushing I need.

The advantage of this clamping fixture in addition to assuring concentricity is that there will be no metal shavings between plates after drilling.

  Sep 27, 2019     match drill spacers - (4 hours)       Category: Rear spar

  Sep 27, 2019     Checking web splice Center       Category: Rear spar

Check web splice

  Sep 27, 2019     Rear web splice       Category: Rear spar

Match drill rear and front web splice

  Sep 27, 2019     match drill spacers webs and capstrips - (4 hours) Category: Rear spar

  Sep 27, 2019     match drill spacers - (4 hours)       Category: Rear spar

  Sep 27, 2019     match drill spacers - (4 hours) Category: Rear spar

  Sep 27, 2019     Final string check - (3 hours)       Category: Rear spar

The front and rear capstrips are matched drilled.
The rear and web are matched drilled
The rear,web and front are now mated together with undersize holes #40

Next step is upsize the holes to #30 for AD4-5.5 RIVETS

  Sep 27, 2019     String used to align web       Category: Rear spar

  Sep 27, 2019     Attach plate       Category: Rear spar

  Sep 27, 2019     align rear web and front capstrips Category: Rear spar

  Sep 27, 2019     right rear Spar assembly Category: Rear spar

Cap strips for top of Spar matched to cap strips for bottom of Spar. Rear cap strips are matched drill to web. Then Rear,Web, and Front capstrips assembled.

  Sep 26, 2019     Match drill rear spar - (8 hours)       Category: Rear spar

Left rear spar match drill finished to final rivet size.

  Sep 24, 2019     Match drill front and rear caps trips to c channel - (8 hours)       Category: Rear spar

  Sep 22, 2019     Cut holes in spar to reduce weight. - (4 hours)       Category: Rear spar

This is a dangerous operation with a fly cutter. Jig is securely attached to drill press. C-channel is securely clamped to jig. Drill press slow speed.