Project: Sportsman   -  
            Listing for Category : aileron(vii)
    (Please mouse-over any icon to get a description of that function).



Categories
  
Builder Name:Kyle Stone   -  
Project:   Glasair - Sportsman 2+2   -   VIEW REPORTS
Total Hours:1859.9
Start/Last Date:Jul 03, 2019 - Jun 30, 2022
Engine:Lycoming IO-390-EXP
Panel:Garmin G3X w/ GNX375 IFR nav, GNC 255 NAV/COM
 
Friendly URL: https://eaabuilderslog.org?s=Sportsman

Home or Last Project Picture

 
Jun 02, 2020     Step #31 - #40 RH Aileron - (6 hours)       Category: Aileron(VII)
Done with RH aileron! I feel like I should earn a badge or something as that riveting in tight places is legit! It did not get much easier the second time around...I only tore open the same cuts from yesterday on my knuckles. Both ailerons are done with the exception of Step #41 on the LH. I'll cut that hole tomorrow.

I need to drill out a few of the pull rivets on the nose ribs as when I was securing the LWR skin I let the UPPER skin flex out a little and it loosened a few of the nose rivets.

gallery thumbnail


gallery thumbnail



 
Jun 01, 2020     Step #40 - rivet trailing edges - (.5 hour) Category: Aileron(VII)
Set Numatix for minimal pressure to meet rivet standard. Too much will make wavy trailing edge.
 
Jun 01, 2020     Step #39 - Rivet fwd servo tab spar to aileron - (.7 hour) Category: Aileron(VII)
 
Jun 01, 2020     Step #38 - Rivet servo tab - (.7 hour) Category: Aileron(VII)
Numatix riveter made easy work of this riveting
 
Jun 01, 2020     Step #37 - Rivet the skin to LWR flanges of the aft ribs - (.5 hour) Category: Aileron(VII)
 
Jun 01, 2020     Step #36 - Rivet the skin and insp. Cover to LWR spar - (1 hour) Category: Aileron(VII)
This went pretty easy....compared to riveting the nose ribs!
 
Jun 01, 2020     Step #35 - Rivet the inspection hole doublers to the skin - (.5 hour) Category: Aileron(VII)
 
May 31, 2020     Step #34 - Drill the trailing edge joggle - (.5 hour) Category: Aileron(VII)
Done...but I forgot to use JB weld for a straight edge. IF you are going to use this method be sure to JB weld a straight edge THEN drill the holes.
 
May 31, 2020     Step #33 - Rivet the skin to the lower flanges of the nose ribs - (1 hour) Category: Aileron(VII)
One would think pull rivets are a 'no brainer��t be sure to have them set flush prior to squeezing. These are a PIA to drill out and replace.
 
May 31, 2020     Step #31 - Rivet the skin to the upper flanges of Nose Ribs - (1 hour)       Category: Aileron(VII)
Damn....that is tight! Lots of band-aid needed. Be patient and be sure bucking bar is set before pulling the trigger. This this sheetmetal deforms quickly. This is where I wish I had a 2x rivet gun instead of a 3x. This one is pretty big for delicate riveting.

gallery thumbnail


gallery thumbnail


gallery thumbnail


gallery thumbnail


gallery thumbnail



 
May 31, 2020     Step #30 - Rivet skin to upper flanges of spar and aft ribs - (2 hours) Category: Aileron(VII)
Yeah...starting to rivet skin. I'm doing the LH first then I'll return for the RH aileron
 
May 29, 2020     Step #28 - rivet rib pairs B & C to their respective hinge brackets - (.7 hour) Category: Aileron(VII)
 
 
May 29, 2020     Step #21 - Install servo tab on aileron - (1 hour) Category: Aileron(VII)
All deburring and cleaning of parts done...ready to start riveting!
 
May 30, 2020     Step #32 - Rivet the ribs and inspection hole doublers to the spar - (2 hours)       Category: Aileron(VII)
This is an error in the assy manual. I am assuming that you need to rivet the nose ribs and flanges to the spar PRIOR to starting to rivet the skins (Step #30). I went ahead and completed both the LH and RH aileron. All ribs, flanges and doubler plates are riveted to the spar.

gallery thumbnail


gallery thumbnail



 
May 30, 2020     Step #29 - Rivet the Hinge Brackets to the spar - (.5 hour) Category: Aileron(VII)
 
May 28, 2020     Step #21 - Install servo tab on aileron - (2 hours)       Category: Aileron(VII)
Yeah...all holes drilled....now its time to disassemble, deburr, and corrosion proof. It sure is nice painting when its 80 degree's outside

gallery thumbnail


gallery thumbnail



 
May 27, 2020     Step #21 - Install servo tab on aileron - (1.5 hours) Category: Aileron(VII)
Tricky setup. Had to work on a few alignment issues with the hinge and spars
 
May 27, 2020     Step #20 - Drill and assemble servo tab - (2.5 hours)       Category: Aileron(VII)
Went as planned...lots of little parts to this servo tab

gallery thumbnail


gallery thumbnail



 
May 26, 2020     Step #19 - Trim ribs and install fwd spar - (.3 hour) Category: Aileron(VII)
 
May 26, 2020     Step #18 - Layout & Mark Servo Tab - (.5 hour) Category: Aileron(VII)
 
May 25, 2020     Step#17 drill inspection hole cover nutplates - (1.2 hours)       Category: Aileron(VII)
Went as planned

gallery thumbnail



 
 
May 24, 2020     Mark and Drill Spar Web Inspection hole doubler - (.5 hour) Category: Aileron(VII)
 
May 24, 2020     Step #14 - Drill Inspection hole cover mounting screws - (.5 hour) Category: Aileron(VII)
 
May 24, 2020     Step #13 - Position and drill inspection hole doublers - (1 hour) Category: Aileron(VII)
 
May 23, 2020     Step #12 - Mark locations Inspection holes - (1 hour) Category: Aileron(VII)
 
May 23, 2020     Step #10 & 11 - Position skin and drill lwr surface - (1.7 hours) Category: Aileron(VII)
Went as planned. Did the LH first then came back and completed the RH
 
May 22, 2020     Step #9 - Cleco remaining ribs to spar and drill - (1 hour)       Category: Aileron(VII)
Went as planned

gallery thumbnail



 
May 22, 2020     Step #8 - Mark & Drill Hing Brackets - (.7 hour) Category: Aileron(VII)
Parts were already drilled with pilot holes from the factory so this saved me time on this step.
 
May 22, 2020     Step #7 - Cleco Nose Rib pairs B & C to spar - (.5 hour)       Category: Aileron(VII)
This seems too easy,....I'm really enjoying doing something different than the wings!

gallery thumbnail


gallery thumbnail



 
May 22, 2020     Step #6 - Dimple the ribs and nutplates - (.7 hour) Category: Aileron(VII)
Numatx squeezer make quick work of these. Had to modify one of my #40 dimple dies
 
May 21, 2020     Step #5 - Position and Drill Nutplates - (1 hour) Category: Aileron(VII)
Yeah..I like nutplates. Took a little while to make a screw fixture to hold the nutplate while drilling.
 
May 21, 2020     Step #4 - Mark and drill counterweight bolt holes - (.7 hour) Category: Aileron(VII)
No surprises
 
May 21, 2020     Step #3 - Drill hinge and actuator bolds - (.5 hour) Category: Aileron(VII)
No surprises
 
May 21, 2020     Step #2 - Mark Rivet Lines - (.5 hour) Category: Aileron(VII)
Pretty straight forward. The edge marking tool I bought a while back makes this task easy!
 
May 21, 2020     Step #1 - Straighten & Deburr Parts - (1 hour) Category: Aileron(VII)
Since most of the parts were already primed at the factory not much work needed.
 


NOTE: This information is strictly used for the EAA Builders Log project within the EAA organization.     -     Policy     -     © Copyright 2024 Brevard Web Pro, Inc.