Jan 07, 2024     Aileron Pushrods - (2 hours)       Category: Wings

Installed the left/right aileron pushrods in the wings. I used a shorter pushrod to confirm that the eyebolts I had already installed inside the fuselage were the right-hand thread type so that I put the correct end first into the wing. Tamped down the rivet heads on the end and added a small film of grease to get it through the bushing about mid-way through the wing. Will wait to torque down the bolt until final rigging is done. On the inspection ports in the wing I noticed that I had not used epoxy so to be sure I went back and added some JB Weld to the rivnut to ensure it doesn't spin in the future upon use.

  Sep 05, 2022     Wings Complete - (1 hour)       Category: Wings

Put the wings up on the wing stand. Thanks to my friend Greg who came over to provide some assistance getting them on there without incident. This is a welcome milestone, and allows freeing up space to spread out the fuselage components now.

There are some cosmetic items to do to the wings later in the finishing stage such as filling rivet heads, removing some of the remaining proseal around tank rivets, etc. When receive the finishing kit from Sling will also install aileron control tubes. Won't install wingtip lights or taxi/landing lights permanently until after paint.

Can now give my full attention to fuselage moving forward.

  Sep 04, 2022     Fuel Tanks - (7.5 hours)       Category: Wings

Attached the tanks with cleco's to the wings and did a final pressure check. This step is a bit of leap of faith as the tanks are riveted (226 rivets each), so any need to remove the tank now means a lot of drilling out rivets. Took some extra time to test tanks before installing - did low pressure water column test again.

One unexpected challenge was that the four AN3 bolts that attach the fuel tank mount angle to the spar are very difficult to get started through the nut plates. Access is at a 90 degree angle in a small space. Had to get some Boelube to help and also ream out spar support angle very slightly from an angle. If were doing it again, would probably leave off rib 1 until after the tank is attached so there is more room to work.

Riveted left and right fuel tanks to wings.

  Aug 30, 2022     WIng Stand - (5 hours)       Category: Wings

In prep for completing wings, built wing stand to store them.

  Aug 24, 2022     Fuel Tanks - (4 hours)       Category: Wings

After checking data points for pressure test on jigs, the values stayed within 3-5% range going up and down all day. Concluded that confident enough to put on the wings and redo the pressure testing there to ensure fitting on the wing did not open up any holes in the seams. Both tanks fit very snug on the wing and it seemed like starting to cleco from the middle (both top and bottom first) was the best approach to get the holes to line up.

After putting left and right fuel tanks on the wings, set up water column test and will now watch for a few days before riveting.

  Aug 23, 2022     Fuel Tanks - (12 hours)       Category: Wings

Over the past few weeks have found and fixed a few leaks on the back channels of both tanks. After latest fixes, have done two types of testing on the tanks. The first was water testing using distilled water where tanks were filled approximately 1/3 of the way. Tanks were turned on both sides to ensure all seams/rivets held and also elevated both ends of the tanks to check end ribs. After confirming this, then took out of the jig and laid on rubber mats on top of table in the configuration the tank would be on the wing (ie fuel cap up and angled towards root end). Tank was then filled with more water to approximately 1/2 and checked - still no leaks. Also checked that both fuel senders were functioning properly with different water levels.

After confirming water tests, then did water column test with 1psi pressurization using a tube to the vent line (703mm of water in tube). At first I thought there may be a leak as the water level varied slightly throughout the day, but it was going both up and down. Upon some research, it appears this can be normal with weather/temperature changes. I will watch for another 24 hours and as long as it stays within this small range, will conclude they are leak free.

I preferred the water method as it was easier to find leaks but the pressure test is helpful as it will be needed to confirm the tank after it has been attached with cleco's to the wing. Once pressure is confirmed when mounted on the wing, then will do final riveting to the wing.

  Aug 20, 2022     Aileron/Flap Fitting - (7 hours)       Category: Wings

Did the final fitting and riveting of the ailerons and flaps to the left and right wing. On the left wing the the 4.8mm rivets on the aileron hinge bracket on rib 7 are rubbing on the rib 14 wing hinge bracket when the aileron is rotated. I added another washer which helped significantly and waiting on factory for additional advice - perhaps one more thin washer will allow for complete clearance. Overall the fitting alignment of the flaps and ailerons came out very good.

  Aug 09, 2022     Ailerons - (6 hours)       Category: Wings

Assembled left and right ailerons, ready for final adjustments/fitment on the wings along with flaps. My kit include the type two eyebolts that do not have grease fittings for the ailerons.

  Jul 24, 2022     Left Fuel Tank - (5 hours)       Category: Wings

Installed back channel on left fuel tank to close it up.

  Jul 17, 2022     Right Fuel Tank - (5 hours)       Category: Wings

Installed back channel on right fuel tank to close it up.

  Jul 15, 2022     Fuel Tanks - (3 hours) Category: Wings

Water tested both left and right tanks before installing back channel.

  Jul 02, 2022     Flaps - (10 hours)       Category: Wings

Cleaned/etched/primed the left/right flap parts and assembled except front rivets to allow twist when aligning with wing.

  Jun 24, 2022     Flaps - (2 hours)       Category: Wings

Dimpled the left/right flap ribs and skins to account for clearance on wing back skin.

  Mar 11, 2022     Right Wing Tip - (6 hours)       Category: Wings

Installed right wing tip. Temporarily installed wingtip light, removed after fitting until after painting.

  Mar 06, 2022     Fuel Tank Seams - (2.5 hours)       Category: Wings

Finished up the interior seams and rivets on the left tank and some interior seams on right tank before running out of proseal. For the rivets used the technique described in this build video at the 30 and 1:23 time marks for how to encapsulate each rivet tail (https://www.youtube.com/watch?v=gTl827JWz68).

  Mar 05, 2022     Right Fuel Tank - (5 hours)       Category: Wings

Inserted internal structure into the skin and riveted the tank while attached to the right wing for proper fit and twist. Will be waiting to add the top flange until after proseal cures so can do leak testing on current work. For Rib 7 on leading edge had to file down an inside notch on rib and shorted the 3.2x8mm rivet to allow enough clearance to pull the rivet as the rib was exactly blocking the hole on the skin.

  Mar 04, 2022     Right Fuel Tank - (7 hours)       Category: Wings

On 3/3 cleaned and etched the right wing fuel skin and ribs for proseal adhesion. On 3/4 constructed the internal structure, including fittings and proceeded with proseal and riveting (sheet 35 in manual). Next step will be to proseal and rivet to skin.

After seeing some rivet line interference during left wing install, I pre-marked the placement of the overflow/vent tube for where it should be after tightening the fitting for the right tank. On the end Fuel Tank Rib 202, the tooling hole at the top that calls for a 4.8mm rivet was actually 6.0mm on both my left and right ribs from the factory. I sourced a 6mm rivet from McMaster-Carr (https://www.mcmaster.com/97524A109/) aluminum with steel mandrel to use.

  Feb 28, 2022     Left Wing Tip - Attached - (2.5 hours)       Category: Wings

Added some aluminum washers with J-B Weld to help keep rivets from pulling through the fiberglass. Did final fitting and riveted left wing tip onto wing.

  Feb 27, 2022     Left Wing Tip - Drilling - (4 hours)       Category: Wings

Final alignment and drilled all holes in the left wingtip. Hole finder was very helpful for drilling the holes on the lower part of rib 14. Drilled and fit left wingtip light with rivnut, wire hole and support rod hole. I will wait to do final wire connection after painting.

  Feb 25, 2022     Left Wing Tip Fitting - (2 hours)       Category: Wings

Riveted the last rib brackets to left wing, installed rib 14 and began test fitting the wingtip. To fit the wing tip properly, cut out some styrofoam to help the tip not compress too much and fit flat against the skin before drilling out rivet holes. Also temporarily added some tabs on the rib 14 to prevent the wingtip lip from riding up and over the flange of rib 14 that it is supposed to butt up against.

  Feb 19, 2022     Left Fuel Tank - Internal Seams - (2.5 hours)       Category: Wings

Did another session of proseal on the left tank. Added sealant to the inner seams and rib rivets. Ordered more proseal to finish left tank and start right tank. Began test fitting the fuel senders and checking the resistance with a multimeter - full reads 180 or above and empty is 0-3 ohms.

  Feb 11, 2022     Left Fuel Tank - (12 hours)       Category: Wings

On 2/10 cleaned and etched the left wing skin and ribs for proseal adhesion. On 2/11 constructed the internal structure, inserted into the skin and riveted the tank while attached to the left wing for proper fit and twist. Will be waiting to add the top flange until after proseal cures so can do leak testing on current work. For Rib 7 on leading edge had to file down an inside notch on rib and shorted the 3.2x8mm rivet to allow enough clearance to pull the rivet as the rib was exactly blocking the hole on the skin.

  Jan 19, 2022     Left Wing Outer Leading Skin - (3.5 hours)       Category: Wings

Riveted outside skin

  Jan 18, 2022     Left Wing Top Skin - (12 hours)       Category: Wings

Over the past week finished up the pitot install and riveting the left wing top skin. The pitot wiring broke the keep it simple rule but was trying to focus on future maintenance of the system when needed. Used PVC pipe to simulate where aileron tube would position when installed to insure clearance. All wires have standoffs and do not touch the airframe to prevent chafing.

  Dec 31, 2021     Pitot Install - (3 hours)       Category: Wings

Working on the installation of the pitot/AOA tube - probably spent too much thinking time vs doing time on this but considered several options and researched others approaches. Had planned on putting on AN fittings to the pitot tubes, flaring the ends and using the push to connect fittings. Test fitting putting the AN connectors up the pitot mast proved challenging for space and also torqueing the fittings through an inspection port possibly in the future for maintenance were considerations. Also after talking to local A&P who does pitot/static testing, decided to try and simplify the connection with just rubber tubbing vs AN fittings.

Did some wire crimping connectors for the first time for the power/ground/signal wires for the control box.

Waiting on pitot connector tubing from Aircraft Spruce as next step to connect the nylon tubing to pitot tubes. Then will mount the controller box to the rib, put in some more standoffs and connect everything.

There are decisions about cutting off the tubes (Garmin calls for leaving 8+ inches for heated one before moving to non-metal connections) and to run above or below the aileron tube that runs right above mast (used PVC pipe to simulate its placement). I decided to bend the tubes below the aileron control tube and towards the inspection port for hopefully easier maintenance in the future if needed.

  Dec 07, 2021     Right Wing Fuel Tank Fitting - (1.5 hours)       Category: Wings

Fitting tank to wing to clear drill all holes

  Dec 05, 2021     Right Wing Fuel Tank Prep - (7 hours)       Category: Wings

Unwrapped and dimpled ribs, channels and skin for right wing tank. Built jig and began fitting together. It took a couple of times trying to cleco the skin to get the holes to line up properly. The fuel tank vent hole on the outer end was a clue that the top channel wasn't lined up correctly and which way to push it to get it aligned. Dimpled and put together the left tank structure.

  Dec 01, 2021     Left Lower Skin - (2.5 hours)       Category: Wings

Riveted lower left root and outer skin.

  Nov 17, 2021     Left Wing Skins - (12 hours)       Category: Wings

From 11/13 to 11/17 finished preparing and dimpling the left wing skins, stringers, inspection hatches. Next step is to prime the inside parts.

  Nov 10, 2021     Right Wing Leading Skin - (2.5 hours)       Category: Wings

Riveted outer leading edge skin.

  Nov 03, 2021     Right Wing Top Skin - Trailing Edge - (3 hours)       Category: Wings

Shortened the 101 3.2x8mm rivets down to 3.2x5.2 and installed on trailing edge. Approach to shortening was to use a scotch-brite wheel on the bench grinder with a template made of three popsicle sticks that would take the rivet down to the first mark consistently. This seems to work better than holding with pliers that scuffs up the edges of the rivet head. Others use a rotary cutting tool I believe, but this method seems to work for me with limited squashing of the material - just my preference.

In my wing kit there were 200+ "RIV-141 3.2x6mm" rivets included that are never referenced in the instructions. From some online resources there is a suggestion to use these 3.2x6mm rivets on the trailing edge skin support, but I thought I would confirm with the factory before using. The response from technical support I received was -
"We have recently stopped using the 3.2 x 6mm rivets because we had issues with the rivet not pulling properly and remained loose. This was time consuming to drill out and replace again. We prefer to use the modified 3.2 x 8mm rivet. You are welcome to use the 3.2 x 6mm rivets.
Both rivet sizes needs to be filed a bit at the bottom after pulling them to make sure they clear the flap.
It should not protrude more than 2mm – 2.5mm below."

  Oct 27, 2021     Right Wing Top Skin - (3.5 hours)       Category: Wings

Attached and riveted right top skin.

  Oct 16, 2021     Left Wing Ribs - (4 hours)       Category: Wings

Riveted ribs to front spar. Attached rear spar.

  Oct 03, 2021     Left Wing Ribs - (3.5 hours)       Category: Wings

Assembled left wing ribs

  Sep 26, 2021     Left Wing Rib Priming - (7 hours)       Category: Wings

Cleaned, etched and primed the left wing ribs and rear spar.

  Sep 25, 2021     Left Wing Rib Prep - (6 hours)       Category: Wings

Finished deburring and dimpling ribs for left wing in preparation for priming.
Created two brackets (2 wide x 1.5 inches) to attach the GAP 26 pitot regulator to rib 10. In comparing placement to either rib 10 or the inspection plate, I selected attaching to rib 10. M3 rivnuts/screws will be used to attach the GAP 26 to brackets.

  Sep 18, 2021     Right Wing Wiring - (2 hours)       Category: Wings

Put in edge protection on each rib across from stringer. Installed wiring for lights. Added standoff on bottom of rib 2 as wires angle up to rib 1 grommet.

  Sep 14, 2021     EAA Technical Counselor Visit - (1.5 hours) Category: Wings

With EAA chapter 168, had a tech counselor come out and review wing and empennage. Very worthwhile and good feedback. Sent in visit report to EAA headquarters.

  Sep 11, 2021     Bottom Skin - (6 hours)       Category: Wings

Built and installed two inspection hatch plates. Riveted bottom skin and bottom root skin.

Items that needed modification:
1) outer inspection hatch rivet that interferes with rib 11 bracket - shortened rivet
2) rib 1 fifth from rear spar rivet that interferes with rib 1 bracket - shortened rivet
3) rear spar 4.0mm rivet interferes with back of rib 9 and bends rib slightly after pulling rivet - consulted factory if should try to drill out and shortened rivet. Factory comment was "All of the TSI wings that we assembled so far have got the rivet pressing against the rib". I decided to leave as is.
4) rear spar 4.0mm rivet appears to interfere with back of rib 4 before pulling rivet (similar to rib 9) - shortened the rivet before pulling to attempt reduction of rib interference

  Sep 04, 2021     Right Wing Skins Prep - (8 hours)       Category: Wings

Cleaned, etched and primed right wing upper and lower skins and stringers.

  Aug 28, 2021     Left Wing Parts Prep - (3.5 hours)       Category: Wings

Unwrapped all left wing parts and began deburring some parts.

  Aug 26, 2021     Right Wing Top Skins - (6 hours)       Category: Wings

Deburred and dimpled top wing skin, top wing root skin, upper and lower stringers. Test fit top skins.

  Aug 24, 2021     Right Wing Bottom Skins - (3 hours)       Category: Wings

Deburred and dimpled the bottom skin and bottom root skin.

  Aug 17, 2021     Right Wing Rear Spar Rework - (2 hours)       Category: Wings

On revision 6.1 of the wing manual on page 4 it says to use 25x 993 (4.8x10mm) on the rear spar double/triple plates. Later when attaching ribs 1-5 to the rear spar it calls for using 991 (4.8x15mm) and 994 (4.0x12mm) rivets. After looking at the rivets more closely they didn't look like they had enough material on the back. Before attaching the rear upper skin support channel, which would make changing these rivets difficult, sent factory a clarification question. They responded that the wing manual instructions were incorrect and that it does need to be 4.8x15mm length rivets. Had to drill out 20 4.8x10mm rivets and replace with 20 4.8x15mm. Before and after pics attached.

  Aug 16, 2021     Right Wing Rear Spar - (1 hour)       Category: Wings

Riveted rear spar

  Aug 15, 2021     Right Wing Ribs - (3 hours)       Category: Wings

Finished riveting ribs to front spar. Attached rear spar.

  Aug 14, 2021     Right Wing Ribs - (2 hours)       Category: Wings

Riveted/bolted the first 7 ribs. Put in the flap torque tube before installing the 7th rib.

  Aug 13, 2021     Right Spar Jig Mounting - (2.5 hours)       Category: Wings

Primed each of the spar countersunk holes (top & bottom). Mounted the spar to the jigs and preparing to rivet ribs.

  Aug 12, 2021     Right Spar Countersinking (bottom) - (3 hours)       Category: Wings

Countersunk second side of the right spar for the 4.0mm skin rivets (185 holes per side).

  Aug 11, 2021     Right Spar Countersinking (top) - (3 hours)       Category: Wings

Countersunk one side of the right spar for the 4.0mm skin rivets (185 holes per side).

  Aug 10, 2021     Ribs - Right Wing - (3 hours)       Category: Wings

Completed assembly of right wing ribs.

  Aug 09, 2021     Parts Prep - (8 hours)       Category: Wings

Cleaned, etched and primed internal structure parts of right wing. Riveted rear spar channel.

  Aug 03, 2021     Parts Prep - (12 hours)       Category: Wings

The last four days doing deburring and dimple where needed on the right wing parts. Did first batch of parts with EkoClean and EkoEtch to get process down before priming.

  Jul 28, 2021     Prime Setup & Parts Prep - (8 hours)       Category: Wings

Removed plastic from right wing parts and began deburring. Ordered a few things missing from the packing list, ex. leading edge rib and trailing rib.
Decided to prime at home using the Stewart Systems EkoPrime system - primarily due to waterborne, non-hazardous chemical composition. Time will tell if this extra effort will be worth it. Built 7H x 16.6L x 9W priming booth with window ventilation fan in 3rd garage space with some zipper access ports so car can be parked out of the Texas sun still when not using the booth. These tarp zippers from Home Depot help make a homemade plastic booth more accessible.

  Jul 09, 2021     Unboxing/Inventory - (2.5 hours)       Category: Wings

Two wing kit crates arrived on 7/9 from CA. Greg, fellow builder friend, came over and was a great help in speeding through the inventory. No damaged parts found so far - amazing given its travels from literally the other side of the world.