Project: Sportsman   -  
            Listing for Category : wing lh (vi)
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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

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Nov 30, 2019     Step 52- Fabricate Inboard Pulley - (1.2 hours)       Category: Wing LH (VI)
Fabricated LH & RH Inboard pulleys....need to prime


 
Mar 14, 2020     Step #65 - Rivet LWR skins - (1 hour)       Category: Wing LH (VI)
Wrapped up a few rework rivets. Have ALL rivets in LWR skins except a few that I need to solve. Outboard aileron bracket assy is interfering in two holes. I already tried to rivet one twice with no success...now I need to go up a size and just use a pull rivet. I still need to set two rivets on the LWR side behind the strut bracket. I may just use pull rivets if I can find ones long enough. Otherwise, its on to building the wing storage stand and starting the RH wing! Yeah!


 
Mar 13, 2020     Step #65 - Rivet LWR skins - (1.5 hours) Category: Wing LH (VI)
Rivet flap coves to LWR skins
 
Mar 12, 2020     Step #65 - Rivet LWR skins - (1.5 hours)       Category: Wing LH (VI)
Help from Lori again this evening...we were able to complete the riveting of the inboard hat sections. I should be able to complete the rest myself....c-channel stiffeners and coves.


 
Mar 11, 2020     Step #65 - Rivet LWR skins - (2.5 hours)       Category: Wing LH (VI)
With the excellent help of Lori...we were able to rivet ALL main ribs to the LWR skins and the outboard hat sections. Lori is a natural Rosie the Riveter! Getting close to wrapping up this wing!


 
Mar 09, 2020     Step #65 - Rivet LWR skins - (1 hour) Category: Wing LH (VI)
Worked on repairing a couple of poorly seated rivets. Tried to begin riveting Main Rib #2 but I'm at a point where i need a "bucker" to ensure good quality.
 
Mar 08, 2020     Step #65 - Rivet LWR skins - (4 hours) Category: Wing LH (VI)
LWR skins riveted to AFT spar successfully. Flap Track brackets installed. A few smiley faces on the outboard side but they are seated nicely so I'll leave them be.
 
Mar 08, 2020     Step #65 - Rivet LWR skins - (4 hours)       Category: Wing LH (VI)
LWR skins riveted to AFT spar successfully. Flap Track brackets installed. A few smiley faces on the outboard side but they are seated nicely so I'll leave them be.


 
Mar 06, 2020     Step #65 - Rivet LWR skins - (1.5 hours)       Category: Wing LH (VI)
All LWR skins riveted to FWD spar along with the Inboard leading edge.


 
Mar 05, 2020     Step #65 - Rivet LWR skins - (3 hours)       Category: Wing LH (VI)
Rivet LWR skins to FWD spar


 
Mar 04, 2020     Step #65 - Rivet LWR skins - (1 hour) Category: Wing LH (VI)
Installed all LWR skins back on wing along with hat sections and stiffeners.
 
Mar 04, 2020     Step #64 - Drill Rivet holes for Flap Track Reinforcement - (3 hours)       Category: Wing LH (VI)
Wow..this took way longer than expected. Lots of measuring and tweaking. I had to open the slots on the upper skins so the flap tracks would have enough clearance. Also had to drill the #40 holes for the Flap Track assy...which was not mentioned in the manual. I feel good about the rivet holes in the spar for the reinforcement angles. Since there we no holes already drilled in the spar I had more flexibility. Painting the parts this evening and will start with the final skin installation tommarow!


 
Mar 01, 2020     Step #63 - Fab Flap Track Reinforcement Angles - (2 hours)       Category: Wing LH (VI)
Completed all fabrication of angles. Will paint after holes are drilled. ANOR complied with on length of braket.


 
Mar 01, 2020     Step #62 - Rivet Leading Edge to FWD Spar - (2 hours) Category: Wing LH (VI)
LH Wing Leading Edge riveting is complete...for new.
 
Feb 29, 2020     Step #62 - Rivet Leading Edge to FWD Spar - (3 hours)       Category: Wing LH (VI)
Top Leading Edge rivets complete. Used my Numatx rivet squeezer and it worked perfectly! Finish up the bottom Leading edge tommarow.


 
Feb 28, 2020     Step #62 - Rivet Leading Edge to FWD Spar - (2 hours)       Category: Wing LH (VI)
Successfully rivets leading edge nose ribs to spar. Pull rivets are soooo easy to install! Next step to rivet leading edge skins to spar with my new Numatex Squeezer!


 
Feb 28, 2020     Step #62 - Rivet Leading Edge to FWD Spar - (2 hours) Category: Wing LH (VI)
Successfully rivets leading edge nose ribs to spar. Next step to rivet leading edge skins to spar with my new Numatex Squeezer!
 
Feb 25, 2020     Step #62 Rivet Leading Edge Assy - (2 hours)       Category: Wing LH (VI)
Joined the leading edge seams together and gently placed the leading edge on the FWD spar. Secured with cleco's and double checked all alignments. Looks good! I'll stat riveting nose ribs tomorrow.


 
Feb 24, 2020     Install Pitot Tube Option - (2 hours)       Category: Wing LH (VI)
Installed Pitot Tube mast and drilled for mounting and Garmin GAP 26 heated AOA pitot tube set-up. Install went well. I used the pitot tube mast from Avery P/N SA-06BL. I purchased the Glasair Pitot Kit which included the newer backing plate. The instructions are not correct and cause more confusion with pictures of old revisions and are not clear. I confirmed with Glasair to use the 'green' primed backing plate and ignore the step for fabricating your own backing plate. The rest of the parts will be used when I get ready to close up the wing and the static ports, that are part of the entire pitot air system.


 
Feb 23, 2020     Step # 62 - Rivet leading edge, cap strips to FWD spar - (1 hour)       Category: Wing LH (VI)
Prep work for step #62. Installed LWR skins, stiffeners, and hat channels. I also need to install the pitot tube mast prior to starting the riveting. I'm optimistic this will be the last time I install the LWR skins!!!!


 
Feb 23, 2020     Step #60 - Rivet Leading Edges together - (2 hours)       Category: Wing LH (VI)
Finished riveting leading edges together. I'm going to wait to rivet them as one complete assy. Until I am ready to install them as I don't want to damage them if they are laying around. Had about 5 rivets that I needed to rework. I learned a lot about flush riveting....what to do and what not to do! Lessons learned.


 
Feb 22, 2020     Step #61- Cut flap track clearance slots in LWR skins - (1.5 hours)       Category: Wing LH (VI)
I still do not have the hang of using the sheet metal shears. The first slot almost ended in disaster when I accidentally snipped a little too far. Was able to buff it out and widen the slot a little. I did practice and master the step drill for corners. This worked out much better than on past hole cutting attempts. The outboard slot I used my portable reciprocating saw with a fine metal bit. Worked perfectly and will use it in the future.


 
Feb 21, 2020     Step #59 - Rivet main ribs, cove ribs to spar - (4 hours)       Category: Wing LH (VI)
That went well! I think I'm getting a little better at riveting overhead rivets. All of Step #59 is complete.


 
Feb 17, 2020     Step #59 - Rivet main ribs, cove ribs to spars - (1.5 hours)       Category: Wing LH (VI)
Putting Humpty Dumpty back together again! Feels good to reassembling the wing...for the last time (I hope). Started clecoing main ribs and flap coves. Need to make a few spacers and make cutout for cable clearance in MR2. Will start riveting when im confident everything is correctly located...tomorrow!


 
Feb 16, 2020     Step #58 - Mount flap pulley brackets - (1.5 hours)       Category: Wing LH (VI)
Went as planned. Modified spar opening for flap cable as the clearance was too small. I'd rather fix that now than when the wing is closed up. I decided to rivet these from the top instead of the bottom (aft) of the spar. Much easier to control and I'm happy with the outcome.

Yeah! All assemblies are attached to the spar...now its time to start putting the skins on!


 
Feb 16, 2020     Step #57 - Mount Flap Bell crank assy - (2.5 hours)       Category: Wing LH (VI)
Finished attaching small brackets to assy w/ my Numatex squeezer...which works perfect. The upside down riveting did not go very well, Thought I was doing a good job but noticed I smashed a number of heads. Drilled out six rivets and reworked. �? ! I finally realized what was casing the difficulty...the spar is flexing up and down when I put pressure to rivet. Once I realized what the issue was I corrected all remaining rivets.


 
Feb 16, 2020     Step #54 - Mount Flap Tracks - (1.5 hours) Category: Wing LH (VI)
Mounted as per assy. Manual. Working on improving my upside down riveting skills. I have a longer rivet set on order that hopefully will make riveting easier. The off-set rivet set is difficult to master
 
Feb 14, 2020     Step #57 - Mount Flap Bellcrank Assy - (.5 hour) Category: Wing LH (VI)
Started mounting process. Fabricated spar attach angles. Orientated bellcrank on spar.
 
Feb 15, 2020     Step #54 - Mount Flap tracks - (2 hours)       Category: Wing LH (VI)
Painted flap track brackets. Assembled Flap Track and mounted inboard to Spar. Confused if I should drill just three holes or 5 holes per bracket. Figure 67 shows five but does not indicate if its inboard or outboard flap track. Would not hurt anything to have more rivets.


 
Feb 15, 2020     Step #58 - Fabricate Flap Pulley brackets - (1 hour) Category: Wing LH (VI)
Fabricated brackets and painted
 
Feb 14, 2020     Step #57 - Mount Flap Bellcrank Assy - (.5 hour)       Category: Wing LH (VI)
Started mounting process. Fabricated spar attach angles. Orientated bellcrank on spar.


 
Feb 14, 2020     Step #53 - Assemble Flap Tracks - (.70 hour)       Category: Wing LH (VI)
Assembled flap tracks. Lots of misinformation within the figure 67. It shows p/n 201-05003-01/02 but this part is not mentioned in the assy instructions...nor are they on the parts list. I also adjusted the edge distance to .25 instead of .22 to maintain proper edge distance. The flanges shown in the figure are not the same as what came in my kit.

Next step is to paint and rivet together....


 
Feb 13, 2020     Step #52 - Mount inboard pulley brackets - (1 hour)       Category: Wing LH (VI)
This went smoothly until I realized that I needed thin washers for the two inboard bolts. There is a doubler plate on the spar that is not shown in the current revision. Need to maintain at least 1.5 threads showing with the nut. Thin washers allowed this to meet the minimum extension w/ at least two threads showing.


 
Feb 13, 2020     Step #51 - Mount Aileron Pulley Brackets - (1.5 hours)       Category: Wing LH (VI)
This took longer than expected as I was a little confused by the directions. I spent some time researching the GAO fourm to ensure I was to "center" the pulley with the bellcrank its self and not the entire assembly. It makes sense that you want it in line with the bellcrank as much as possible. I need to get better clamps.....this was a little tricky to keep it from moving around. Welding clamps would work well. I also need to research to see if I need to install cable guides. I've read the SB 63 which I think is for the cable guides in the fuselage but I want to double-check that I don't need any in the wing.


 
Feb 12, 2020     Step #50 - Mount Aileron Bellcrank and hinge - (2 hours)       Category: Wing LH (VI)
Used my new Numatx HTS=C3K squeezer on the little side brackets...sweet! I made a base to mount the Numatx on and its much more compact now. I mounted the aileron cove using flush rivets under the side brackets. Having an issue with the length of my rivet set. I need a longer one! The offset I have is just too difficult to use with one person. I ordered a 7/5" rivet set today. I'll drill out a few of the rivets that have smiley faces and wait to finish this on until the extended rivet set arrives. Feels good to be riveting stuff on the spars!


 
Feb 09, 2020     Step #49 - Position and Drill outboard aileron hinge assy - (.5 hour)       Category: Wing LH (VI)
Went as per instructions. Feels good to be connecting all the sub-assemblies I made during T-Day break on the spar.


 
Feb 09, 2020     Step #48 - Position and drill aileron bellcrank & aileron hinge assembly - (2.5 hours)       Category: Wing LH (VI)
Positioned and drilled as per instructions. I did NOT widen aileron pushrod slot as it was to the dimensions as noted on Figure 57. I'm assuming since my spars are new then this modification is not needed. I'm always cautious when drilling the spar so I took my time orientating myself to where I was and where I am going. I will countersink holes for AC3 so they do not interfere with brackets. Got to use my right angle drill attachment and it worked well.


 
Feb 08, 2020     Step #43 - corrosion proof internal wing parts - (6 hours)       Category: Wing LH (VI)
Scotchbrite all parts, clean with acetone, primer with Duplicoat self etching primer. All went well. I used 5 cans of spray paint for all main ribs, nose ribs, flap coves, aileron coves, and stiffeners. Wear mask when sanding and painting!


 
Feb 06, 2020     Step #42. Countersink FWD Spar - (2.5 hours)       Category: Wing LH (VI)
Done! All went well with countersinking...I think! We'll see how I did when I fit up all the skins. Finished deburring all holes on FWD and AFT spars. Ready for Step #43 - primer all internal parts then start putting this beast back together!


 
Feb 05, 2020     Strep #42 - Countersink Spars - (1.5 hours) Category: Wing LH (VI)
Countersink .025 and .040 holes on forward spar.
 
Feb 03, 2020     Step#42 - Countersink FWD Spar Flanges - (2 hours)       Category: Wing LH (VI)
Spent a lot of time double checking first round of countersinks with scrap. Finally dove into drilling the .032 countersink holes. All went as planned.


 
Feb 02, 2020     Step #41 - Dimple Skins - (3.5 hours)       Category: Wing LH (VI)
Yeah! All done with step #41. There was an error in the build manual that caused me some frustration and back stepping. The note on page 99 (12/29/04, rev a), Step #41, Note #5. Should be simply stated as:

Nose Rib 6 & Nose Rib 12 should have #30 diameter holes on both the upper and lower leading edge skins. These are the skin splices at BL 69.0 and BL 130.75.

To improve the build manual, Step #36, last paragraph (page #86) should be corrected to state the same thing as noted above for note#5, step #41. The current language is incorrect as it referencing the wrong BL location. This has caused me to backtrack to resolve the issue. Fortunately, making holes bigger is easy so the problem was solved and just cost time.


 
Jan 30, 2020     Step #41 - Dimple Skins - (1.5 hours)       Category: Wing LH (VI)
Making corrections to the Seam Splits on the Nose Skins. It seems I missed this in step #35. However, there is some confusion and contradiction in Step #41 notes, #5. The seam I THINK they are talking about is BL130.75, not 144.95.


 
Jan 29, 2020     Step #41- Dimple Skins - (2.5 hours)       Category: Wing LH (VI)
Used DRDT-2 to dimple all Leading edge skins. Work well and made quick work of dimpling. Need to investigate nose rib hole size at NR 6 & NR 12. I did not drill them up to #30 and this step is confirming that they are #30. I might have missed this somewhere.


 
Jan 27, 2020     Step #41 - Deburr skins - (1 hour) Category: Wing LH (VI)
Yeah...LH Skins, Main Ribs, Nose Ribs, Cove & Ailerons ribs, and leading edge skins are all deburred and ready for dimpling. A total of 18 hours in deburring these parts. Whew.
 
Jan 26, 2020     Step #41 - Deburr skins - (1.5 hours) Category: Wing LH (VI)
Almost done with deburring ALL skins for LH Wing. One more to go then I get to start dimpling and countersinking the spars.
 
Jan 25, 2020     Step #41 - Deburr skins - (4 hours)       Category: Wing LH (VI)
Only two more skins left to deburr! The power screwdriver set-up is working great! Moved the deburr tip from the Avery deburr tool to the power driver and it's saving my wrist from carpal tunnel.


 
Jan 24, 2020     Step #41 - Deburr skins - (2 hours) Category: Wing LH (VI)
Leading Edge all deburred and now I'm onto the top skins deburring.
 
Jan 23, 2020     Step #41 - Deburr skins - (3 hours)       Category: Wing LH (VI)
Working on the deburring leading edge skins. Should be ready to dimple this weekend


 
Jan 20, 2020     Step #41 - Dimple skins & deburr - (2.5 hours) Category: Wing LH (VI)
All deburring complete with the exception of the leading edge skins and main skins.
Found one hole I missed drilling up to #30...had to remount leading edge skin to drill up.
Spent time reviewing what is getting flush rivets vs. round rivets. Directions are a little confusing when talking about "tip rib" then a semi-colon...which is not proper punctuation.
 
Jan 14, 2020     Step #41 - Dimple Skins, Deburr - (3 hours) Category: Wing LH (VI)
Deburred all holes on Main Ribs
 
Jan 12, 2020     Step #41 - Dimple Skins - (4.5 hours)       Category: Wing LH (VI)
The fun begins! Lots of deburring and nocking down edges. All stringers and hat sections are ready for cleaning then paint. Moving on to the skins next.


 
Jan 10, 2020     Step #40 - Finish Drilling Root rib - (1 hour)       Category: Wing LH (VI)
Drilled Root Rib FWD and AFT Spar hole for screws. Its really hard to maintain .01 tolerances with a hand drill! All of my margins were maintained and I did not violate on the skins.


 
Jan 09, 2020     Step# 39 - Position & Drill Upper Skin Stringer channels - (1.5 hours)       Category: Wing LH (VI)
Went as planned....much easier with a helper!


 
Jan 07, 2020     Step #38 - Position and Drill LWR skin stiffners - (1.5 hours) Category: Wing LH (VI)
DrilledI all stiffeners on LWR skin. Did not remove yet as I'm reviewing the Pitot Tube installation steps next.
 
Jan 04, 2020     Step #36 - Position & Drill LWR Skin hat sections - (3.5 hours)       Category: Wing LH (VI)
Installed all LWR hat sections. Drilled all #30 hole as per instructions.


 
Jan 03, 2020     Step #37 - Drill Upper Hat Sections - (5 hours)       Category: Wing LH (VI)
Positioned, drilled all Upper Hat Sections. Drilled all FWD & AFT spar flange holes to #30 as per instructions. My inboard skins did not need the additional holes drilled for the hat sections (see picture)


 
Jan 02, 2020     Step #34 & 35 - adjust & mark hat section stiffeners - (1.2 hours)       Category: Wing LH (VI)
Completed as per instructions. Why does step #35 say 'trim��iffeners but then the note says to wait until hole are drilled. This should be moved to the end of step #36 as its confusing.


 
Jan 01, 2020     Step #25 - Position & drill LWR inboard skin - (4.5 hours)       Category: Wing LH (VI)
Done. Nothing too tricky here. Leading edge skin did not need trimmed as it met almost perfectly with the center leading edge skin.


 
Dec 31, 2019     Step #24 - Position & Drill LWR & Center skins - (4.5 hours)       Category: Wing LH (VI)
Worked on trimming leading edge and main skins to get the edge spacing just right. I'm happy with all the edges except where the outboard leading edge overlaps the center leading edge. It will have to do as I don't want to violate margins. Its about compromises and I've learned its hard to put metal back on once you've removed it.

Completed drilling center skin. Step #24 is done!

I'm loving my new Makita LXT Sub-compact drill. The air drill work well but the noise is pretty loud with the compressor running all the time and when I'm really making progress with the air drill the compressor can't keep. The Makita is light and the charge is lasting a long time.


 
Dec 27, 2019     Step #23 - Finish Drilling Upper skins - (1.5 hours) Category: Wing LH (VI)
Reinstalled all leading edge skins and top skins. Ready to start drilling tomorrow!
 
Dec 27, 2019     Step #22 - Trim Leading Edge Skin - (2 hours)       Category: Wing LH (VI)
Trimmed all TOP leading edge skins. Used my Toko ski edge Panzer file holder which worked great. I tried to snip some of the edge first with tin snips but these are difficult to control for small tolerances. The Panzer file takes just a little more time but the finished product is much better and there is no risk in damaging the edge.


 
Dec 27, 2019     Step #20 - Position and Drill Upper Main Skins - (1.5 hours)       Category: Wing LH (VI)
Done....everything seemed to fit nicely


 
Dec 20, 2019     Step #20 - Position & Drill Upper Main Skins - (2.5 hours)       Category: Wing LH (VI)
Sorted skins from crate. Positioned Outboard skin and drilled. Positioned Center skin and started to drill. I soon realized why the upright supports for the wings are modified to be skinny as they interfere with the trailing edge of the skin. I think I`ll replace them with a 2x4 upright.


 
Dec 19, 2019     Step #19 - Finish drilling Leading Edge Skins - (2.2 hours)       Category: Wing LH (VI)
Drill Drill Drill. Upper Spar Drilled.


 
Dec 19, 2019     Step #18 - Install FWD Spar caps - (1 hour)       Category: Wing LH (VI)
Made Spar Caps for both wings. Installed on LH wing.


 
Dec 19, 2019     Step # 17 - Drill Center Leading Edge Skin - (2 hours)       Category: Wing LH (VI)
Since I installed the Inboard skin prior to the Center skin I had to remove the Inboard skin to install the center skin. I thought I was going to have gap issues between the overlaps but everything fit nicely. I pulled a straight line across both leading edges and it looks good. I`m not sure if I was just lucky but these skins installed pretty easily with little issue. Onto the next step!


 
Dec 18, 2019     Step #17 - Center Leading Edge - Cont`d - (1 hour)       Category: Wing LH (VI)
Started install of center leading edge skin. Will continue tomorrow


 
Dec 18, 2019     Step #16 - Index Drill Outboard leading edge skin - (1.5 hours)       Category: Wing LH (VI)
Went as planned...no issues with mounting skin


 
Dec 17, 2019     Step #17 - Inboard Leading Edge Skin Install - (4 hours)       Category: Wing LH (VI)
I spent plenty of time reviewing and pulling the correct parts from the crate for all the leading edge skins. I double checked the jog alignment and ensured everything was still proper. I was so excited to start fitting the first skin on the wing I inadvertently started with the 'inboard��in instead of the 'outboard skin��I had it all aligned and ready to drill when I realized I should be working on the other end of the wing. I reviewed Step #17 - Center and Inboard skin and concluded it was fine to continue as I did not want to undo all my straps and cleco clamps if it would still work. I successfully drilled and clecoed the inboard leading edge skin! Yeah...feels good to start skinning the wing. Tomorrow I`ll start on the outboard wing install.


 
Dec 17, 2019     Checking Main Rib (MR5) tightness - (1 hour)       Category: Wing LH (VI)
I was concerned because one of the main ribs (MR5) seems to be under some stress and bows in and out slightly. I inspected the rib and compared it to others but found no differences. It seems to be just a smidge too long and binding crossway. I sanded down some primer in the area of contact on both the FWD & AFT spars and this seemed to help a little. I`ll check on this later to see if is of concern.


 
Dec 17, 2019     Step #15 - Mount Strut beam - (.5 hour) Category: Wing LH (VI)
Finished torquing upper FWD spar bolts. While I was doing research on the final bolt size for the main root ribs I realized I did NOT need torque the bolts to the spar as it appears I`ll be removing and reinstalling the strut beam. A simple notation in Step #15 to NOT torque bolts would be helpful.
 
Dec 16, 2019     Step #15 - Mount strut beam assy - (3 hours)       Category: Wing LH (VI)
Installed Strut beam. Wow...modifying that little washer was tricky. Happy with how the holes lined up. Manual is missing instructions to drill up to 1/4��les on spars and strut beam attach angles.....took a little research to ensure this was the correct step. Don`t want to drill the wrong size holes in the spars! These little bits of missing information really add up. I have a buddy building a Carbon Cub currently and this is what separates a `frustration free` build (Carbon Cub) vs. being frustrated (Sportsman) on a regular basis because the Assy. Manual has not been updated for 16 years! I`m still happy with the product thus far...just venting a little after a lot of 'research��eded when a simple statement in the manual would have resolved the issue.


 
Dec 16, 2019     Step #12 - Mount Ribs to Spars - Cont`d - (6 hours)       Category: Wing LH (VI)
Finished all the drilling for Nose ribs, Main Ribs, and Cove ribs. Everything went well. I spent ample time double/triple checking the BL measurements to ensure I had everything oriented properly. The Tables listed on pp. 25 & 26. Use caution on Figure 7.1. On to step #13!


 
Dec 15, 2019     Step #12 - Mount Ribs to Spar - (1.5 hours)       Category: Wing LH (VI)
Mounted outboard nose rib, main rib, aileron cove to end of wing. This was a little tricky getting everything to cooperate when mounting to the wing jig...and NOT allowing the wing to move too much! Double checked everything and now I1m ready to drill the spars next!


 
Dec 15, 2019     Step# 12 Mount Ribs to Spars - (4 hours)       Category: Wing LH (VI)
Worked through prints to ensure I was mounting the Nose Ribs, Main Ribs, Flap Cove and Aileron cove ribs correctly. My progress was slowed due to a number of parts being labeled incorrectly and/or conflicting information between reference prints.

Item #9 and #10 are either labeled incorrectly (swapped) on the part OR Figure 17 is incorrect. The P/N`s on Figure 7.1 are not correct for these items either. I installed them with the correct orientation based table 3 and description w/n instructions.

Item #46 & #47 are either labeled incorrectly (swapped) on the part OR Figure 17 is incorrect. The P/N`s on Figure 7.1 are swapped too. I installed them with the correct orientation based on table 2 and description w/n instructions.

Aileron cove ribs were correct however there is a discrepancy between Figure 7.1, Cove # 5. It shows `inboard` on Figure 7.1 and `outboard` on Figure 17 AND Table 5. I installed as `outboard` (Item #13, P/N 201-00007-01).

Otherwise...all went well!


 
Dec 14, 2019     Step #11 - Root Rib Assy - Cont`d - (1.5 hours)       Category: Wing LH (VI)
Rivet final assembly. Everything went well. The rib fits very tight. The height is perfect as the root rib doublers will have a nice rivet margins. The tightness seems to be from the width both FWD and AFT spars. Maybe remove some paint?


 
Dec 14, 2019     Step #11 - Reinforce Main Root rib - cont`d - (5 hours)       Category: Wing LH (VI)
Drilled all #40 holes, match drilled 3/16��les through aft & forward spars. Deburr; cleaned; primed all parts. Ready for rivets next!

I wonder how many times throughout this build I will drill a hole in my thumb? Ouch...#40 hole right on the end.


 
Dec 13, 2019     Step #11 - Reinforce Root Main Rib - (1.5 hours)       Category: Wing LH (VI)
Trimmed Root Rib doubler (LH). A band saw sure would make this step easier. Hack saw and high speed cut off disc. Lots of clean up with the scotch bright disc grinder!


 
Dec 13, 2019     Step #7 - Mark rivet lines - Again - (1 hour)       Category: Wing LH (VI)
Marked rivet lines on forward spart


 
Dec 12, 2019     Step #55 & 56 - assemble flap bellcranks - (1.5 hours)       Category: Wing LH (VI)
Finished assembly of flap bellcranks. Had to wait for Loctite 609 to arrive as I could not source it locally. Pressed in bearing housings and bearings. Completed Step 56 but did NOT torque nuts or install cotter pin. Will check fit when installing then torque and insert cotter pin.


 
Dec 06, 2019     Step #55 - Assemble Flap bellcrank - (1.5 hours)       Category: Wing LH (VI)
Riveted flap bellcranks assemblies (LH & RH), Riveted upper & lower bellcrank bracket assembly


 
Dec 06, 2019     Step #51 & 52 assemble outboard & Inboard pulleys - (1 hour)       Category: Wing LH (VI)
Completed assembly of LH outboard pulley. Completed assembly of both inboard pulleys. Torqued to 40��unds, installed cotter key and marked w/ torque paint


 
Dec 06, 2019     Step #48 Assemble Bellcranks assy Category: Wing LH (VI)
Assembled Bellcrank as per figure 56.
 
Dec 06, 2019     Step #48 Assemble Bellcranks assy       Category: Wing LH (VI)
Assembled Bellcrank as per figure 56.


 
Dec 06, 2019     Step 47 - Rivet Aileron Bellcrank Bracketss - (.5 hour)       Category: Wing LH (VI)
Went smoothly. Bucking with rivet set was much more efficient than hand squeezing


 
Dec 06, 2019     Step #46 - Rivet aileron bellcrank - (.5 hour)       Category: Wing LH (VI)
Had to modify rivet set just a little so it did not ding bearing


 
Dec 06, 2019     Step #45 - (.5 hour) Category: Wing LH (VI)
Riveting complete on flanges
 
Dec 05, 2019     Step #45 Rivet and finish hinge assemblies - (2 hours)       Category: Wing LH (VI)
There is something about riveting that is so satisfying! Hand squeezed all rivets except for ones closet to the lower flange.


 
Nov 27, 2019     Step #47 - Assemble Aileron Bellcrank Bracket - (1.5 hours)       Category: Wing LH (VI)
LH & RH fabricated....need to deburr then paint prior to riveting


 
Dec 04, 2019     Painting subassembly parts - (2 hours)       Category: Wing LH (VI)
Scrubbed parts with #7447 scotch bright pads, cleaned with acetone, painted with self-etching Dupli-Coat Primer

Temp was cooler than I would have liked in Garage. Had to ventilate which caused temp to drop.


 
Dec 03, 2019     Deburr all sub assemblies - (2.5 hours)       Category: Wing LH (VI)
Lots of deburring little holes! Ready to clean and paint!


 
Nov 30, 2019     Step 51 - Fab Outboard Pulley Brakets - (1.5 hours)       Category: Wing LH (VI)
Fabricated brackets. First screw-up! Need to re-make one of the pulley brackets as I did not pay attention to the flange direction and had it backwards. Set aside for now and order aluminum flange when needed. P/N 602-04101-3. 6061-T6, .063 x 7/8�� 1/2��Might be able to make locally. Only need one more bracket...3��ngth.


 
Nov 29, 2019     Step #56 - Assemble Flap Bellcrank Bracket - (1 hour)       Category: Wing LH (VI)
Fabricated angles and drilled. LH & RH complete except for deburr & painting, then rivet together.


 
Nov 29, 2019     Step #55 - Assemble Flap Bellcrank - (2 hours)       Category: Wing LH (VI)
Step complete up to painting and mounting...


 
Nov 27, 2019     Step #46 - Assemble Aileron Bellcrank - (.5 hour)       Category: Wing LH (VI)
need to paint then rivet


 
Nov 26, 2019     Step #44 - Fit and Drill Aileron Hinge Components - (3 hours)       Category: Wing LH (VI)
Fabricated and fit hinge components. I mixed up one of the angles for the inboard aileron attach hinge so I cut a slot in one of the non-notched angles. Reading ahead on the instructions it appears this should work fine.
Instructions were a little unclear on how #82 bearing arm double align....apparently I aligned it differently than shown in Figure 52. Reading ahead in the installation I don't think this will be an issue.


 
Nov 23, 2019     Step 14 - Assemble the Strut Beam - (5 hours)       Category: Wing LH (VI)
Drilled and mounted all parts for both LH & RH Strut beams. Need to paint brackets. Wait to torque bolts until fitting onto spar.


 
Nov 20, 2019     Step #10 - square rib flanges & mark rivet lines - (2 hours)       Category: Wing LH (VI)
squares and marked rivet lines. Ribs were pretty square out of the box!


 
Nov 16, 2019     Step #4 -6 Not Needed....but wait...I found a problem - (4 hours)       Category: Wing LH (VI)
I had moved on to Step #7 because the manual indicated that step #4 - 6 were completed at the factory. After realizing in Step #10, my spars are missing the doubler plates that were supposed to be mounted at the factory. I had all the parts but they were not installed. This cost me a number of hours trying to figure out what the problem was. The Root Rib that you make in Step #10 was too short. Luckily, I did not drill or cut much of anything for Step 10 as it just did not make sense. I re-measured my jig brackets, checked the parts again and again but could not figure out what was missing until I looked at some pictures of other builders and realized the doubler plates were missing.

I sent an email to Glasair and Jake Bruns helped immediately. This was on a Thursday (11/21) and they are closed on Friday so I needed to wait until Monday for a resolution. Jake said they were making a new set of spars and shipping them out to me ASAP. They didn't even hesitate on making the problem right! Jake tried to get them shipped on Wed (11/27) prior to the T-Day shut-down but the truck could not make it out until Monday (12/2). I really appreciate his effort on getting this done! Since I realized I could not continue on the spars I moved on to the subassemblies for both wings.


 
Nov 13, 2019     Step #2, #3, 8, 9 Fabricate Wing Jig Spar Brackets; install brackets; level spars - (10 hours)       Category: Wing LH (VI)
I tried to make these out of 2x2x1/4 steel angle as I was having a hard time locating 2x2x3/16" aluminum angle where i live (Grand Junction, CO) as my options are limited. I used my drill press to drill the holes and I was not happy with the accuracy of the holes. I learned a few lessons: a) buy new drill bits (good grade, not cheap ones) b) steel is much harder to drill & cut than aluminum!

After reaching out to another local EAB builder he has some 2x2x1/4" aluminum angle laying around so he brought it over and I remade the brackets. These new ones worked out great. I also found that using my cheap-o plastic miter box jig to cut the aluminum with a hacksaw made the cut more accurate too! I don't have a band saw so I'm cutting everything with the hacksaw.

My workbench surface is very level (I was surprised) but I still wanted to ensure the spars are level end-to-end. I built a water level, which was really fun, to ensure everything is level...and stays that way. I also pulled a string line from end to end and ensured no bowing when leveling the AFT spar.


 
Nov 12, 2019     Step 1 - Fabricate Wing jog Framework - (5 hours)       Category: Wing LH (VI)
I took two of my 5' original EAA Workbenches and cut them down to a lower height. I then built another EAA workbench that was 6' long at the same height. I bolted them together (top and bottom) so they are essentially one, 16' workbench now. I used 4x4 wooden post. I researched the uprights for many hours and looked at various designs from other builders and decided to go with wood 4x4 post as the instructions indicate. My logic is that I live in an area with pretty stable RH and I don't plan on these wings sitting in the jigs for years. We'll see how this "plan" works out in the future!


 
Nov 29, 2019     Aileron Support Bracket - (2 hours)       Category: Wing LH (VI)
Drilled and assembled Aileron Support Brackets LH, RH wings


 
Nov 29, 2019     Flap Bell Crank Assy - (2 hours)       Category: Wing LH (VI)
Drilled and assembled Flap Bellcrank assy. for LH and RH wings


 


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