Project: Sportsman   -  
            Listing for Category : wing rh (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

Home or Last Project Picture

May 19, 2020     Step #65 - Rivet LWR skins - (3 hours)       Category: Wing RH (VI)
Yeah! Right-wing lower skins are all done and right-wing is to the quick build stage. I just saved myself $15,000! Left-wing took 17 16.5 hours for this step. Right-wing took 12 hours. Nice improvement and better quality. I'll need to return to the left-wing and make some repairs on a few suspect rivets. On to the Flaps and Ailerons then I'm done with book #1!

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May 18, 2020     Step #65 - Rivet LWR skins - (2 hours)       Category: Wing RH (VI)
Enlisted the help of Lori The Bucker! She did great and really enjoyed helping out. It really goes so much faster with a helper!

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May 17, 2020     Step #65 - Rivet LWR skins - (3 hours)       Category: Wing RH (VI)
Keep on riveting! I'm running low on a few key rivets....need to take an inventory and order more for the when I close up the top skins. Flap reinforcement brackets came out nice. One rivet was a tad too close but it set fine so I'm leaving it.

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May 16, 2020     Step #65 - Rivet LWR skins - (3 hours)       Category: Wing RH (VI)
Feels good to start the final step in the Wing Assy. Section! Riveted LWR skins to FWD spar. Did all I could...now I need my Lori the Riveter!

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May 14, 2020     Step #64 - Drill Rivet holes for Flap Track Reinforcement - (3 hours)       Category: Wing RH (VI)
Glad I had my other wing to reference as the directions for this section are terrible. Anyhow....reinforcement angles painted and mounted and ready for riveting.

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May 13, 2020     Step #62 - Rivet Leading Edge to FWD Spar - (2 hours)       Category: Wing RH (VI)
More riveting...and now we are done! I really enjoy using the hydraulic riveter....wish I could use it in more places.

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May 12, 2020     Step #62 - Rivet Leading Edge to FWD Spar - (3 hours) Category: Wing RH (VI)
More riveting....
 
May 11, 2020     Step #62 - Rivet Leading Edge to FWD Spar - (1 hour) Category: Wing RH (VI)
Riveting.....
 
May 10, 2020     Step #62 - Rivet Leading Edge to FWD Spar - (.5 hour) Category: Wing RH (VI)
Double checked everything under the leading edge and secured with clecos
 
May 10, 2020     Step #60 - Rivet Leading Edges together - (1 hour)       Category: Wing RH (VI)
Connected leading edges at the seams to form one long leading edge. Placed on FWD Spar and ready to start riveting

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May 09, 2020     Step #60 - Rivet Leading Edges - (2 hours) Category: Wing RH (VI)
Almost done...waiting to join them all together until I can set them directly on the FWD Spar
 
May 08, 2020     Step #60 - Rivet Leading Edges - (1.7 hours) Category: Wing RH (VI)
Keep on riveting....
 
May 08, 2020     Step #60 - Rivet Leading Edges - (1.70 hours)       Category: Wing RH (VI)
Dang...had the pressure too high on the first rivet and dinged the skin...darn. Luckily, is on the Tip Rib and will be covered by the wing tip cover. Outboard done

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May 07, 2020     Step #60 - Rivet Leading Edges - (.7 hour) Category: Wing RH (VI)
Setup fixture and organize parts. Ready to start riveting
 
May 07, 2020     Step #59 - Rivet main ribs, cove ribs to spar - (1.5 hours)       Category: Wing RH (VI)
Yeah...done with riveting all spars, coves to FWD and AFT spars. Found the key to riveting is to make some leverage for my arm while holding the rivet gun firm. Don't try to rivet with your left hand...it never works out. Walk around to the other side of the wing and rivet with your right hand. This is another good reason to get s 2x instead of a 3x rivet gun. The 3x is heavy!

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May 06, 2020     Step #59 - Rivet main ribs, cove ribs to spar - (1.5 hours) Category: Wing RH (VI)
 
May 05, 2020     Step #59 - Rivet main ribs, cove ribs to spar - (1.5 hours) Category: Wing RH (VI)
 
May 04, 2020     Step #59 - Rivet main ribs, cove ribs to spar - (1.5 hours) Category: Wing RH (VI)
 
May 02, 2020     Step #59 - Rivet main ribs, cove ribs to spar - (1.5 hours)       Category: Wing RH (VI)
This is the stage where you really feel like you are moving forward. Putting the ribs on and getting ready to rivet to the spar.

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May 02, 2020     Step #58 - Mount Flap Pulley brackets - (1 hour)       Category: Wing RH (VI)
Mounted as per the manual. I need to open up the gap a little more for the cables. I noticed on my other wing that I removed a lot of metal to give plenty of clearance. I need to review the manual to determine how I figured this out....not sure now!

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May 02, 2020     Step #57 - Mount Flap Bellcrank Assy - (1.5 hours)       Category: Wing RH (VI)
Mounted as per the manual. My riveting is finally getting more consistent.

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May 01, 2020     Step #54 - Mount Flap tracks - (2 hours) Category: Wing RH (VI)
All went well...mounted Flap Track brackets.
 
May 01, 2020     Step #53 - Assemble Flap Tracks - (2 hours)       Category: Wing RH (VI)
Flap tracks assembled and mounted. No issues...went as planned! I had to drill out one rivet and it was a perfect removal. Of course....using the drill press made it easier!

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Apr 28, 2020     Misc. painting - (1 hour)       Category: Wing RH (VI)
Painting a few odds and ends prior to riveting

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Apr 27, 2020     Step #42. Countersink FWD Spar - (2 hours) Category: Wing RH (VI)
Finished drilling countersinks after I received my new bit. All holes countersunk!
 
Apr 27, 2020     Step #58 - Fabricate Flap Pulley brackets - (.7 hour) Category: Wing RH (VI)
Made bracket...waiting on paint to complete
 
Apr 27, 2020     Step #53 - Assemble Flap Tracks - (1 hour) Category: Wing RH (VI)
Drilled holes...waiting for paint to prime
 
Apr 27, 2020     Step #52 - Mount inboard pulley brackets - (.5 hour)       Category: Wing RH (VI)

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Apr 26, 2020     Step #51 - Mount Aileron Pulley Brackets - (2 hours) Category: Wing RH (VI)
 
Apr 25, 2020     Step #50 - (2 hours) Category: Wing RH (VI)
Riveting complete. Drilled out two bad rivets.
 
Apr 25, 2020     Step #50 - (2 hours) Category: Wing RH (VI)
Riveting complete. Drilled out two bad rivets.
 
Apr 25, 2020     Step #49 - Position and Drill outboard aileron hinge assy - (.30 hour)       Category: Wing RH (VI)
Done...removing aft spar from jig makes it much easier to drill and rivet.

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Apr 24, 2020     Step #48 - Position and drill aileron bellcrank & aileron hinge assembly - (.5 hour)       Category: Wing RH (VI)
Made a mistake and had the wrong size pulley on the bracket. Also noticed that I had the brackets backwards. Drilled new access holes for linkage connectors and fixed pulley issue. I need to slow down to speed up!

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Apr 24, 2020     Step #48 - Position and drill aileron bellcrank & aileron hinge assembly - (2.5 hours) Category: Wing RH (VI)
Worked on positioning aileron bellcranks
 
Apr 24, 2020     Step #48 - Position and drill aileron bellcrank & aileron hinge assembly - (2.5 hours) Category: Wing RH (VI)
Worked on positioning aileron bellcranks
 
Apr 21, 2020     Step #43 - corrosion proof internal wing parts - (1.5 hours)       Category: Wing RH (VI)
Finished painting other side of all parts.

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Apr 22, 2020     Step #43 - corrosion proof internal wing parts - (1 hour) Category: Wing RH (VI)
Unmasked parts and found a few stringers that I forgot to paint!
 
Apr 20, 2020     Step #43 - corrosion proof internal wing parts - (4 hours)       Category: Wing RH (VI)
Finished deburring, scuffing, and acetone parts. Set-up paint booth and ready to paint

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Apr 19, 2020     Step #43 - corrosion proof internal wing parts - (3 hours)       Category: Wing RH (VI)
Had a helper today....makes quick work when two people are working on the prep work. Should be ready to paint soon.

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Apr 18, 2020     Step #42. Countersink FWD Spar - (2.5 hours) Category: Wing RH (VI)
All was going well until I broke my #30 countersink bit! Rats....had to order another one from Clevland Tools. No worries....plenty of deburring and prep for painting to do in the meantime.
 
Apr 17, 2020     Step #41 - Dimple Skins - (1.5 hours)       Category: Wing RH (VI)
Finish dimpling leading edge ribs and tip rib.

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Apr 16, 2020     Step #41 - Dimple Skins - (2 hours)       Category: Wing RH (VI)
Dimple skins and leading edge skins

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Apr 15, 2020     Step #41 - Dimple skins & deburr - (1.5 hours)       Category: Wing RH (VI)
Deburred all skins....set-up dimple system and ready to roll. Dimpled test piece and all looks good. Will finish dimpling on Thursday then start deburring rest of parts and getting them ready for paint.

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Apr 14, 2020     Step #41 - Dimple skins & deburr - (1 hour)       Category: Wing RH (VI)
Deburring all skins prior to dimpling. Note to self..don't over deburr rivet holes! Especially the ones that will dimpled.

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Apr 13, 2020     Step #41 - Dimple skins & deburr - (2 hours)       Category: Wing RH (VI)
Here we go! Lots of deburring and dimpling is about to begin! Today I mostly removed all the skins, nose ribs, main rib, flap coves, and aileron ribs. Vacuumed all the metal shavings.

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Apr 12, 2020     Step #40 - Finish Drilling Root rib - (1.5 hours) Category: Wing RH (VI)
Completed drilling and countersinking holes. Not sure what they mean by a 11/32 diameter? The AN509-10R10 screw that is countersunk is much larger than that. I took the screw and held it in the location to determine if the skin needed trimming. It did on the lower spar but upper was just fine.
 
Apr 11, 2020     Step #37 - Drill Upper Hat Sections, skins - (1.5 hours)       Category: Wing RH (VI)
Yeah..done with all drilling of holes in Upper/Lower spars, stiffeners, hat channels

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Apr 10, 2020     Step #37 - Drill Upper Hat Sections, skins - (1 hour) Category: Wing RH (VI)
Continue with drilling all the #30 holes in upper and lower spars
 
Apr 09, 2020     Step #37 - Drill Upper Hat Sections - (2 hours) Category: Wing RH (VI)
Drilling #30 holes...
 
Apr 09, 2020     Step #39 Drill upper skin stringer channels - (1 hour) Category: Wing RH (VI)
 
Apr 08, 2020     Step #37 - Drill Upper Hat Sections - (1 hour) Category: Wing RH (VI)
Adjust hat channels
 
Apr 07, 2020     Step #37 - Drill Upper Hat Sections - (1 hour) Category: Wing RH (VI)
Set skins and upper stiffeners (step 39)
 
Apr 07, 2020     Step #37 - Drill Upper Hat Sections - (1 hour) Category: Wing RH (VI)
Set skins and upper stiffeners (step 39)
 
Apr 07, 2020     Step #38 - Position and Drill LWR skin stiffeners - (1.3 hours) Category: Wing RH (VI)
Install these before removing LWR skins...it will save you time!
 
 
Apr 04, 2020     Step #35 - Trim Stiffener flanges & Mark rivet lines - (.5 hour) Category: Wing RH (VI)
Done
 
Apr 04, 2020     Step #34 & 35 - adjust & mark hat section stiffeners - (.5 hour) Category: Wing RH (VI)
Done
 
Apr 04, 2020     Step #34 & 35 - adjust & mark hat section stiffeners - (.5 hour) Category: Wing RH (VI)
Done
 
Apr 03, 2020     Step #25 - Position & drill LWR inboard skin - (2 hours)       Category: Wing RH (VI)
Much easier 2nd time around. The directions for this step are just way more complicated than they need to be. Everything installed just fine with no surprises. Feels good to have all the upper and lower skins positioned and drilled. I know there is a lot of deburring in my future but that's okay!

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Apr 02, 2020     Step #24 - Position and Drill Lower outboard & Center Main Skins - (2 hours) Category: Wing RH (VI)
Drill....Drill....Drill.
 
Apr 02, 2020     Step #24 - Position and Drill Lower outboard & Center Main Skins - (2.5 hours) Category: Wing RH (VI)
Trimmed outboard and center leading edges and created a nice clean gap between all the edges (upper and lower) skins. Time to start drilling holes!
 
Apr 01, 2020     Step #24 - Position and Drill Lower outboard & Center Main Skins - (1.5 hours)       Category: Wing RH (VI)
Set all LWR skins and drilled preliminary holes. Removed skins and trimmed edges and removed rivet line protective coating with a soldering iron.

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Mar 31, 2020     Step #24 - Position and Drill Lower outboard & Center Main Skins - (1 hour) Category: Wing RH (VI)
Note that the directions are referring to the wrong steps. It should read "Step 20 through 23". I also waited to remove the leading edge skins for trimming until this step or else you remove them twice....once for the Upper Skins and second for the LWR skins. If you wait until this step it saves time! This is the step where I also remove all the protective cover from over the rivet lines. It makes it less messy when drilling and you can see the hole better.
 
Mar 30, 2020     Step #24 - Position and Drill Lower outboard & Center Main Skins - (1 hour) Category: Wing RH (VI)
Started the installation of LWR outboard and Center skins. Will work on trimming the edges next work session.
 
Mar 30, 2020     Step #23 - Finish Drilling Upper Main Skins - (1.5 hours) Category: Wing RH (VI)
Done..lots of drilling and used all my #40 cleco's.
 
Mar 29, 2020     Step #23 - Finish Drilling Upper Main Skins - (2 hours)       Category: Wing RH (VI)
Returned all upper skins to spars and drilled FWD spar and ribs. Will finish drilling LWR spar and coves tomorrow.

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Mar 28, 2020     Step #22 - Trim Leading Edge Skin - (3 hours) Category: Wing RH (VI)
Trimmed FWD edges of Upper skins. Will trim leading edge...edges when I remove them for the LWR skin trimming process. This saves some time as you only remove the leading edge once, not twice. My edges need only a minor amount trimmed.
 
Mar 27, 2020     Step #20 - Position and Drill Upper Main Skins - (2.30 hours)       Category: Wing RH (VI)
2nd time around is so much easier. Having another wing to compare to helps too. Hundreds of holes later and cleco's upper skins are positioned and semi-drilled w/ #40.

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Mar 27, 2020     Step #19 - Finish drilling Leading Edge Skins - (3.5 hours)       Category: Wing RH (VI)
Done...installed all Leading edge skins and drilled to #40. Compressor can barley keep up with the constant air drilling. Ready for main skins :-)

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Mar 25, 2020     Step #18 - Install FWD Spar caps - (.5 hour) Category: Wing RH (VI)
Installed as instructed. I cut them when I made the LH wing. Rounded edges more to fit better into the FWD spar. Nice and flush with better edge margins than on the LH wing
 
Mar 24, 2020     Step #17 - Center & Inboard Leading Edge Skin Install - (2.5 hours)       Category: Wing RH (VI)
All went well. Maintained 1 1/8 rivet spacing on both sides....barely. Seems like either the pilot holes on the leading edge fwd spar could be moved down by 1/16" and make the entire process easier. The amount of force on the nose ribs concerns me when pulling the skin into place. Its tight...no doubt about that!

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Mar 24, 2020     Step #16 - Outboard Leading Edge Skin Install - (1.5 hours) Category: Wing RH (VI)
With a little encouragement....the margins were met on both the upper and lower skins. Outboard skin is set..onto the center and inboard skins.
 
Mar 24, 2020     Step #16 - Outboard Leading Edge Skin Install - (1.5 hours)       Category: Wing RH (VI)
With a little encouragement....the margins were met on both the upper and lower skins. Outboard skin is set..onto the center and inboard skins.

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Mar 22, 2020     Step #16 - Outboard Leading Edge Skin Install - (.5 hour)       Category: Wing RH (VI)
Sorted out the leading edge skins and started the install.

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Mar 22, 2020     Step #15 - Mount strut beam assy - (2.5 hours)       Category: Wing RH (VI)
Went as expected. Making the custom washer takes the longest! Seems like there is a better solution for this but I could not think of one other than milling the surface flat on the leading edge side of the FWD spar. I opted to stick with the plans and make a custom washer.

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Mar 21, 2020     Step #12 - Mount Ribs to Spar - (4.5 hours)       Category: Wing RH (VI)
Everything is so much easier than the first go around! All went according to my revisions and notes that I learned on the LH Wing! I still need to rivet MR2 together but I want to paint it too. I'll wait until I pull them all out and paint then rivet it together.

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Mar 20, 2020     Step #11 - Reinforce Root Main Rib - (3 hours)       Category: Wing RH (VI)
Painted main rib. Riveted rib, drilled 3/16" holes in FWD & AFT spars, nose and flap cove ribs. Installed with a little push..much better than the LH wing.

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Mar 19, 2020     Step #11 - Reinforce Root Main Rib - (5.5 hours)       Category: Wing RH (VI)
Completed all fabrication and drilling for the main root rib. Jake was a huge help at the factory by providing a few tips on how to make the ends of the doublers fit better by clamping them in a vise while drilling the last three holes. I did this on both the FWD and AFT ends and it seems to fit much better when test fitting. Beveling the ends of the doublers also helped. Time to paint then rivet...

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Mar 18, 2020     Step #11 - Reinforce Root Main Rib - (1.5 hours)       Category: Wing RH (VI)
Taking my time to make sure it fits better than the left main Root rib, which is super tight to get in and out.

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Mar 18, 2020     Step #10 - square rib flanges & mark rivet lines - (1.5 hours) Category: Wing RH (VI)
Pretty straight forward. New edge marking tool makes this task very easy
 
Mar 17, 2020     Step #2, #3, $#7, 8, 9 Fabricate Wing Jig Spar Brackets; install brackets; level spars - (4.5 hours)       Category: Wing RH (VI)
Productive afternoon making RH Wing brackets....marking rivet lines, installing brackets and leveling FWD and AFT spars. So much easier the second time around. I spent 8 hours in the LH Wing just leveling last time...today took around 1 hour.

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