Project: wstoelting   -  
            Listing for Category : wings
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Builder Name:Wade Stoelting   -  
Project:   Just - Highlander   -   VIEW REPORTS
Total Hours:788.9
Total Flight Time:
Total Expense:$68417.69
Start/Last Date:Oct 09, 2019 - No Finish Date
Engine:Yamaha Apex
 
Friendly URL: https://eaabuilderslog.org?s=wstoelting

Home or Last Project Picture

Apr 29, 2024     Travel Struts - (1.5 hours)       Category: Wings
Preparing airplane for trailer transporting to Montana. Removed front leading edge spar pins, and rotated wings back. Fabricated wing travel support/secure struts from 1/2 square tubing. Secured wings for trailering.

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Apr 24, 2024     Jury Strut Install - (3 hours)       Category: Wings
Located and drilled jury strut holes in weldment and the bracket straps that attach jury strut to wing struts. Painted brackets. Fastened in place with hardware.

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Jan 24, 2024     Installed Wings - (4 hours)       Category: Wings
Moved plane and wings from garage to hangar. Installed wings after arriving at hangar. Still have a few hardware installation fixes but it sure looks like a plane now.

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Sep 11, 2022     Flap Springs       Category: Wings
Plane Fun Aircraft now sells these alternative flap springs which perform better than the tension type provided in the kit.

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Oct 04, 2021     Aileron Fabric - (6.5 hours)       Category: Wings
Applied covering to remaining aileron.

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Oct 02, 2021     Right Side Elevator - (6 hours)       Category: Wings
Covered starboard elevator.

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Sep 30, 2021     Rudder Fabric - (9 hours)       Category: Wings
Applied fabric and tapes to rudder. Used Polyfiber system as with everything else.

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Sep 24, 2021     Horizontal Stabilizer Fabric - (3.5 hours)       Category: Wings
Finished Left Stabilizer by adding fabric and tapes to unfinished side.

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Aug 14, 2021     Left Aileron - (8.5 hours)       Category: Wings
Purchased more MEK. Completed fabric application to left aileron.

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Aug 08, 2021     Left Flap - (9.5 hours)       Category: Wings
Added fabric to left flap. Process same as right flap work. Takes a lot of time to do properly. Skill gets better with each time.

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Aug 04, 2021     Right Flap - (4.5 hours)       Category: Wings
Added leading edge tapes. Finished trailing edge tape on bottom side. Applied Polybrush to all surfaces.

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Aug 01, 2021     Left Flap - (4 hours)       Category: Wings
Applied fabric to flap. Used one piece. Applied adhesive to trailing edge. Wrapped, First applied Polytak to leading edge, and ribs. Drilled ribs for rivets. Used adhesive to bond the fabric. Did low temp shrink to work out the wrinkles on leading edge. Bonded to tip and root ribs. Used thinned Polytak t I bond leading edge. Trimmed fabric, overlapped tip and root ribs. Shrunk fabric at 250F, 300F and 350F.

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Jul 30, 2021     Elevator Trim Tab - (3.5 hours)       Category: Wings
Applied fabric to elevator trim tab. Used one piece. Used Polytak along leading edge, wrapped and overlapped, applied adhesive between fabric pieces. Trimmed. Bonded edges. Shrunk. Applied polybrush to all surfaces. Applied tapes to all edges.

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Jul 27, 2021     Right Wing Fabric - (3.5 hours)       Category: Wings
Used 6 inch tape for leading edge and two 3 inch tapes for trailing edge.

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Jul 25, 2021     Right Wing Fabric - (4.0 hours)       Category: Wings
Added Chordwise tapes over ribs top side and bottom side. Added tapes to false ribs and span wise over rear spar on underside. All were first marked out with #2 pencil and straight edge to get bond lines straight. Precoated fabric where tape was to be applied with Polybrush. Then applied wet, brushed over then dried then second coat over tapes.

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Jul 22, 2021     Right Wing Fabric - (3.5 hours)       Category: Wings
Finished fabric edges at trailing and leading edge butt rib and tip rib. Smooth fabric along leading edge. Bonded to gussets around strut fittings and control pulley areas. Installed reinforcement tape on under side ribs and secured fabric with large head rivets before final shrinking because of under camber wing. Used iron shrunk at 250F upper and lower sides. Next will shrink at final 325F or so.

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Jul 19, 2021     Right Wing Top side Fabric - (3.0 hours)       Category: Wings
Unrolled fabric across top side of wing. Cut off roll. Used Polytak to apply to trailing edge. Bonded leading edge. Bonded to wing tip rib and rib two. Trimmed leading edge fabric to chalk line for two inch overlap. Used iron at 225 to shrink top side, then rotated to shrink bottom side.

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Jul 18, 2021     Right Wing Fabric - (3 hours)       Category: Wings
Installed/applied fabric to lower side of wing. Process is going more smoothly after learning from process on left wing.

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Jul 18, 2021     Magnetometer - (.7 hour)       Category: Wings
Fabricated a mount for GRT magnetometer to be installed on/in right wing wing tip rib.

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Jul 03, 2021     Polyfiber SuperFil       Category: Wings
Purchased more Polyfiber Superfil to smooth out rib to trailing edge joints, welded joints and etc to improve overall fit and finish of fabric applications. Expensive with shipping when comparing to autobody filler.

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Jun 22, 2021     Left Wing Fabric - (7.0 hours)       Category: Wings
Bonded lower side ribs, shrunk fabric at 250F, applied reinforcement tapes,, installed rivets, securing fabric to ribs, shrunk at 300F, Applied gussets and fabric dollies over bracket areas, chordwise tapes over ribs top and bottom sides using the polyfiber system instruction.

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Jun 05, 2021     Left wing Fabric - (6 hours)       Category: Wings
Continue to work on wing as time permits. Learned plenty along the way, next wing will go better. Had to iron out several wrinkles in fabric, will cut holes for wing strut mounts prior to attaching lower side fabric next time. Applied upper fabric with 2 inch bond line on leading edge, 1 in trailing edge. Did initial 250 degree heat shrink with iron, continued to trim for jury strut and control pulleys. Used soldering iron to burn holes through fabric for rivets in lieu of lacing. Applied reinforcing tape, burnt holes, installed rivets. Next is to shrink at 300 and final 350 prior to applying Polybrush and tapes.

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May 14, 2021     Lower Side Fabric-Left Wing - (4 hours)       Category: Wings
First piece of fabric being applied. Still have a few wrinkles to iron out prior to applying top fabric. So much more to do just to finish this wing.

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Apr 28, 2021     Fabric Supplies       Category: Wings
Anti-chafe tape, rib lacing, needle. $20 for tape, $50 for thread, $20 for needle, $20 for shipping. Crikey things add up.

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Apr 25, 2021     Polybrush on Leading/Trailing Edges - (1.5 hours)       Category: Wings
Mixed Polybrush with Reducer and applied two coats to leading edge, and trailing edge and fabric plates.

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Mar 21, 2021     Prep for Covering Wings & Control Surfaces - (15 hours)       Category: Wings
Applying Superfil, sanding, and etc. Tedious effort to blend leading and trailing edges with spars and ribs. Still not perfect, but might say good enough.

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Feb 28, 2021     Pitot and Static Tube Routing - (1 hour)       Category: Wings
Routed two tubes from Pitot and static location, into rear spar at rib 2 and extend tubing out the end of spar at root.

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Feb 18, 2021     Left Aileron Fabric Plates - (3 hours)       Category: Wings
Added joggle to fabric plates to install on underside of custom leading edge. Trimmed to fit. Applied chromate primer to underside. Drilled mounting holes, countersunk, applied epoxy to mating surfaces, located in place, installed rivets.

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Jan 22, 2021     Filled Leading Edge Cuff Joint - (4 hours)       Category: Wings
Scuffed and solvent cleaned spar surface along bonded cuff. Marked flush surface line on spar. Applied tape along line to limit area for filler application. Mixed up super light filler from Polyfiber. Applied to upper and lower mating cuff edge to spar area. Allowed overnight curing and then sanded.

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Jan 22, 2021     Filled Leading Edge Cuff Joint - (4 hours) Category: Wings
Scuffed and solvent cleaned spar surface along bonded cuff. Marked flush surface line on spar. Applied tape along line to limit area for filler application. Mixed up super light filler from Polyfiber. Applied to upper and lower mating cuff edge to spar area. Allowed overnight curing and then sanded.
 
Dec 29, 2020     Smoothing Out Imperfections - (3.5 hours)       Category: Wings
Mixed up light weight filler and applied to left wing at rib/trailing edge interface. False rib to front spar joints. Applied to wing tip/strobe light mounts.

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Dec 27, 2020     Varnish False Ribs, Rear Spars, Bracing - (3.5 hours)       Category: Wings
Mixed up varnish, brushed on false ribs, rear spars, flaps and aileron false ribs and ribs.

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Dec 27, 2020     Wing Tip &Strobe Light Mounts - (2 hours)       Category: Wings
Epoxied light mounts. Fabricated wood closeouts for wingtip at aileron area.

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Dec 26, 2020     Nav Light Mounting To Wing Tips - (4 hours)       Category: Wings
Fabricated aluminum brackets for mounting nav/strobe/position lights. Pressed treaded inserts into brackets. Bonded to inside of fiberglass strobe mounts.

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Dec 26, 2020     Nutplates, Adel Clamps, Fuel Line Category: Wings
Parts for fabric plates, and mounting fuel system.
 
Dec 21, 2020     Left Wing Control Pulley Mounts - (6 hours)       Category: Wings
Position flap pulley mount near rib#2. Trimmed rib cap. Aligned with flap control horn. Drilled, cleco in place. Abraded mating surfaces, applied epoxy, riveted in place. Did the same with aileron pulley mounts. Slotted trailing edge for flap spring. Positioned trailing edge, drilled and countersunk rivet mounting holes, abraded mating surfaces. Epoxy and rivet in place.

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Dec 21, 2020     Left Wing Control Surfaces - (1 hour)       Category: Wings
Mixed epoxy adhesive, solvent cleaned mating surfaces, applied epoxy to hinge plates and riveted in place.

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Dec 21, 2020     Left Wing Control Surface Hinges - (2 hours)       Category: Wings
Located supports from top of wing contour. Placed flap and aileron in position with spacers to offset from wing trailing edge. Located hinges, clamp in place, drill through hinge mounting plate holes through rib webs. 6 hinge pairs.

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Dec 16, 2020     Flap Hinges- Left Wing - (1.5 hours)       Category: Wings
Temp installed trailing edge. Clamped straight edges to ribs on top side of wing, and 1/8 spacer to position flap. Match drilled hinge mounting holes,, reamed 3/16th hinge bushing hole x6. Positioned hinges and clamped in place.

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Dec 14, 2020     Left Wing Aileron Leading Edge - (2 hours)       Category: Wings
Fitted leading edge to aileron. Drilled rivet holes, countersink each one. Abraded and solvent cleaned spar and metal leading edge. Applied epoxy to 14 ribs, positioned, applied epoxy to main ribs, placed leading edge in place, installed rivets.

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Dec 10, 2020     Leading Edge Cuffs - (3 hours)       Category: Wings
Cut relief cuts in leading edge cuffs for lift strut bracket and jury strut bracket. Sanded mating surface, solvent cleaned surfaces applied Dynaflex 260 sealant to mating surface. Taped into place, positioned per template.

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Dec 07, 2020     Leading Edge materials Category: Wings
One tube of Dynaflex 230 sealant to affix leading edge to front wing spars. 1/16ths thick basswood straps for aileron leading edge.
 
Dec 07, 2020     Left Flap Leading Edge - (1 hour)       Category: Wings
Cut leading edge clearance cutouts around hinges and bellcrank.

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Dec 06, 2020     Left Wing False Ribs & Cable Guided - (2 hours)       Category: Wings
Marked out locations of 14 false leading edge ribs. Abraded wing stringer and leading edge. Solvent cleaned, applied epoxy to ribs and installed. Used templates to locate control cable holes through main ribs near trailing edge. Drilled pilot hole then opened hole for nylon cable guides. Cut tubing, swaged one end of each, 16 pieces. Installed into ribs, swaged other end. Used heat gun and pressed ends with metal strip to swage.

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Dec 03, 2020     Left Aileron Hinges&Bell Crank - (1.5 hours)       Category: Wings
Abraded hinges and bell crank mating surfaces, abraded spar at mounting locations. Solvent cleaned surfaces. Mixed up and applied epoxy to mating surfaces, installed hinges and bell crank with CCP44 rivets. Located leading edge and marked locations of hinges and bell crank. Cut 5/8 inch slots at those locations.

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Dec 02, 2020     Left Wing Trailing Edge - (1 hour)       Category: Wings
Lightly abraded inside surface of trailing edge. Masked wing main rib locations. Applied chromate primer.

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Nov 28, 2020     Left Wing Flap - (2 hours)       Category: Wings
Trimmed fiberglass flap leading edge to fit. Marked locations for leading edge ribs. Mixed epoxy and applied to false rib edges. Installed and used tape to keep square, applied epoxy to flap ribs and positioned flap leading edge. Taped in place.

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Nov 24, 2020     100 pack of CCP45 rivets Category: Wings
Rivets to install brakes on ailerons.
 
Nov 24, 2020     Left Wing Flap - (1.5 hours)       Category: Wings
Clamped left flap and aileron together with 1/4 inch spacer. Centered both surfaces with wing, marked centerline of wing ribs 1,2,4,5,7,9 onto front spars. Centered and clamped hinges and bell crank on flap with markings. Secured with hose clamps. Set position of hinge points with measurements from trailing edge. Located flap to wing to confirm alignment. Transfer drilled #30 holes from brackets to spar. Removed hose clamps to access other holes to transfer. Cleco in place and drilled remaining holes. Mixed up epoxy, solvent cleaned surfaces, applied epoxy and riveted flap hinges and bell crank in place.

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Nov 20, 2020     Right Wing Tip - (1.5 hours)       Category: Wings
Taped along molded in scribe mark. Trimmed off fiberglass at scribe line. Hung aileron on wing, marked notch area for aileron travel, cut notch in wing tip. Installed wing tip onto wing, transferred drill holes in fiberglass for mounting.

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Nov 18, 2020     False Rib Install, Right Wing - (1 hour)       Category: Wings
Selected 14 false ribs. Spaced and marked positions on front spar and stringer two false rib locations evenly spaced between main ribs. Abraded surface, silent cleaned. Mixed and applied epoxy to false rib mating edges, squarely placed and applied fillers of epoxy. 14 places.

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Nov 17, 2020     Right Flap Fabric Plates - (1 hour)       Category: Wings
Drilled matching rivet holes in aileron leading edge with fabric plates. Sanded mating surfaces of aileron leading edge around hinges and flap control bracket. Sanded sheetmetal fabric plates. Solvent cleaned surfaces. Mixed epoxy and applied to mating surfaces, riveted plates to edge of leading edge.

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Nov 15, 2020     Fitting Fabric Plates- Right Wing - (2 hours)       Category: Wings
Prepared fabric plates for control surface hinges, trimming to fit, adding joggle to aileron hinge fabric plates to work with metal leading edges. Applied epoxy to wing fabric plates, installed in place on ribs with rivets.

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Nov 13, 2020     Fabric Plates - Strut Brackets, Control Surfaces - (1.5 hours)       Category: Wings
Located and matched drilled fabric plates with strut brackets. Riveted in place. Fit fabric plates for aileron and flap control brackets. Drill plates, match holes into leading edge of control surfaces.

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Nov 12, 2020     Fabric plates Right Wing - (1.5 hours)       Category: Wings
Fitted fabric plates for aileron and flap control pulleys. Clearanced opening, installed nutplates to fabric plates and trailing edge of right wing.

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Nov 11, 2020     Right Wing Trailing Edge - (1 hour)       Category: Wings
Countersunk rivet holes in trailing edge, Abraded mating surfaces, applied epoxy and riveted trailing edge to rivets in place.

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Nov 10, 2020     Wing Control Cable Guides - (1 hour)       Category: Wings
Cut nylon tubing in 2 inch pieces, 16 pieces for right wing. Heated one ened of each piece and presses end to create a bulb. Installed pieces into previously drilled wing rib holes. Heated and pressed remaining end of tube pieces to lock in place in ribs.

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Nov 08, 2020     Aileron Hinge Brackets, Cable Rib Holes - (2 hours)       Category: Wings
Lightly sand, clean right wing aileron hinge brackets. Painted. Printed out rib templates for control cable locations. Placed templates to ribs and drilled with 1/8" drill. Then drilled holes with 5/16th drill. Cut cable bushings.

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Nov 06, 2020     Engine Mount Powder Coat       Category: Wings

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Nov 03, 2020     Flap Hinges Right Wing - (2 hours)       Category: Wings
Located flap to hinge brackets, position flap flat with top contour and 1/8 inch gap. Clamp brackets in place, drilled through bracket holes through rib web. Removed flap, epoxied and riveted hinge brackets in place.

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Nov 03, 2020     Flap Hinges Right Wing - (2 hours) Category: Wings
Located flap to hinge brackets, position flap flat with top contour and 1/8 inch gap. Clamp brackets in place, drilled through bracket holes through rib web. Removed flap, epoxied and riveted hinge brackets in place.
 
Oct 18, 2020     Right Wing Trailing Edge Mounting - (1 hour)       Category: Wings
Position Trailing Edge, drill #40 holes into each rib thru trailing edge. Counter sink holes in metal trailing edge.

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Sep 14, 2020     Left Aileron Leading Edge Bonding - (2 hours)       Category: Wings
Drilled Aileron Leading edge for rivets into rib caps. Abraided mating surfaces, solvent cleaned, epoxied in place.

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Sep 07, 2020     Aileron Pulley Blocks Right Wing - (3 hours)       Category: Wings
Position pulley blocks on rear spar, clearance rib cap. Drill, and cleco in place. Abrade and clean mating surfaces, apply epoxy to mating surfaces, install rivets.

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Sep 01, 2020     Flap Pulley Block -Right Wing - (2 hours) Category: Wings
Position Pulley Block to inboard side of rib 2, trim rib cap, align with control bracket on flap, mark location, drill and locate with clecos, abrade and clean rear spar and block. Apply epoxy and rivet in place.
 
Aug 31, 2020     Left Aileron Leading Edge Splice - (.5 hour)       Category: Wings
Completed joining the two leading edge pieces with splice. Used 3/32nd solid rivets.

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Aug 20, 2020     Epoxy Left Quarter Window - (1 hour)       Category: Wings
Masked and applied epoxy at rear quarter window to fuselage.

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Aug 20, 2020     Epoxy Left Quarter Window - (1 hour)       Category: Wings
Masked and applied epoxy at rear quarter window to fuselage.

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Aug 19, 2020     Right Wing Return Spring - (1 hour)       Category: Wings
Aligned and attached flap spring bracket to flap spar. Slotted leading edge for flap spring.

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Aug 15, 2020     Left Aileron Leading Edge - (2.5 hours)       Category: Wings
Mr. Naoya Kishimoto assisted with modifying aileron rib leading edges for custom leading edge. Marked cut line on ribs, and 14 false ribs. Trimmed away material for fitting metal leading edge. Installed leading edge splice to one of two pieces. Marked rivet location, drilled #40 holes, countersunk for flush rivets. Installed rivets with squeeze and impact gun.

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Aug 15, 2020     Right Wing Flap Pulley Block - (2 hours)       Category: Wings
Temp installed flap, positioned pulley block, cut rib cap for clearance, clamped pulley block with pulley in place. Marked trailing edge for flap return spring slot. Drilled out 2 -3/4" holes and then removed material in between.

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Aug 15, 2020     Pulley Blocks - (1 hour)       Category: Wings
Marked and drilled #30 holes in 6 pulley block mounts for wings. Sanded mating surfaces free of paint.

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Aug 12, 2020     Varnished Left Wing - (2 hours)       Category: Wings
Applied Poly Fiber epoxy varnish to wood ribs of left wing.

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Aug 05, 2020     Left Wing Root Rib Lightening - (2 hours)       Category: Wings
Marked out cutout pattern similar to right wing. Completed cutouts, bonded and riveted stiffener to underside rib cap.

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Aug 04, 2020     Flap Leading Edge-Right Wing - (1 hour)       Category: Wings
Abraded spar of flap where false ribs were to be bonded. Applied epoxy to false ribs and to ribs. Mated leading edge and secured in place.

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Aug 03, 2020     Left Wing Tank Cover - (2.5 hours)       Category: Wings
Aligned sheetmetal over ribs one and two. Located holes aligning with nutplates in ribs. Drilled. Installed tank and aligned sheetmetal to locate hole for tank filler spout. Marked and cutout hole.

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Aug 02, 2020     Butt Ribs and Trailing Edge Finish - (2 hours)       Category: Wings
Installed reinforcement to butt ribs, epoxy and riveted in place. Applied paint to butt ribs. Applied Zinc Chromate primer to inboard surface to right wing trailing edge.

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Jul 27, 2020     Aileron Hinge and Bellcrank Mounting - (1.5 hours)       Category: Wings
Abraded mounting surfaces of hinges, bell rank and front spar. Solvent cleaned, applied epoxy and riveted in place.

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Jul 22, 2020     Aileron Leading Edge Right Wing - (2 hours)       Category: Wings
Cut relief clearance cuts around hinge and bell crank locations for hinge brackets from main wing.

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Jul 16, 2020     Aileron Leading Edge Fillers - (1 hour)       Category: Wings
Purchased 1" x 24" x 1/16" basswood to use as filler to close gaps between false ribs and leading edge preventing distortion when fabric covering is shrunk.

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Jul 15, 2020     Flap Leading Edge - (1 hour)       Category: Wings
Cut and sanded leading edge hinge and bell crank relief cutouts so flap can be installed.

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Jul 14, 2020     Right Flap Hinges and Bracket Attach - (.5 hour)       Category: Wings
Abraded mating surfaces of hinges and control bracket and flap spar. Cleaned surfaces with acetone. Applied epoxy adhesive to matting surfaces. Cleco'd in place. Installed CCP-44 rivets.

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Jul 13, 2020     Varnish and Aileron False Ribs - (2 hours)       Category: Wings
Applied second coat of epoxy varnish to tight wing ribs. Applied epoxy adhesive to aileron false ribs and installed into right wing aileron. Cleco'd aileron leading edge in place to secure false ribs in place for adhesive to cure.

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Jul 12, 2020     Right wing root rib stiffener - (.8 hour)       Category: Wings
Placed metal stiffener. Marked for holes, drilled #30. Transferred holes to lower rib cap. Abraded mating surfaces and applied epoxy, riveted in place.

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Jul 12, 2020     Root Rib Web Out - (3 hours)       Category: Wings
Decided to remove material from rib #1 right wing similar to patterns on other ribs. Drew out pattern, marked center points for radius. Used hole cutter at locations then used small, reciprocal saw to remove material. Sanded cutouts. Installed fuel tank for verification.

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Jul 10, 2020     Epoxy Varnish to Right Wing - (2.5 hours)       Category: Wings
Applied by brush epoxy varnish to wood ribs and gussets of right wing.

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Jun 28, 2020     False Rib Install In Right Aileron Leading Edge - (2.5 hours)       Category: Wings
Positioned leading edge, marked centerline for Control bracket and hinges. Marked offsets and measured. For other false rib locations. Sanded fiberglass leading edge bonding areas. Applied epoxy to ribs and installed. 24 hour cure.

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Jun 27, 2020     Fuel Tank Cover Leading Edge Mouny - (1.5 hours)       Category: Wings
Located piece in place on front spar and marked with Sharpie. Drilled for rivets on rib 1 and 2 rib caps. Scuffed mating surfaces, solvent cleaned. Mixed up epoxy and applied to mating surfaces. Positioned, clamped in place with straight edge, installed rivets and allowed 24 hour cure.

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Jun 14, 2020     Slotted Trailing Edge Left Wing - (1 hour)       Category: Wings
Slotted trailing edge for aileron and flap hinges at ribs 5, 7 and 9.

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Jun 13, 2020     Flap and Aileron Rt Wing Brackets - (1 hour)       Category: Wings
Drilled rivet holes into front spar of aileron and flap for hinge brackets and bellcranks for right wing.

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Jun 12, 2020     Flap and Aileron Leading Edges - (3 hours)       Category: Wings
Cut fiberglass leading edge for flap to length. Trimmed long edges so edges mated with rib caps. Cut metal aileron leading edge to length. Cut slots to clear hinges.

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Jun 10, 2020     Left Wing Trailing Edge - (2.5 hours)       Category: Wings
Marked, set punch drilled for nutplates in trailing edge for fuel tank cover mount. Cut trailing edge pieces to length to meet at rib web.

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Jun 07, 2020     Right wing trailing edge. - (2.5 hours)       Category: Wings
Cut trailing edge pieces to length for right wing. Chained drilled and filed slots for aileron and flap hinges.

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Jun 02, 2020     Aileron and Flap Install-Right Wing - (2 hours)       Category: Wings
Placed wing underside up. Clamp straight edges on wing ribs to support aileron &flap. Cleaned up epoxy around flap spar and rib so hinge can be placed.

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May 31, 2020     Butt Rib Left - (2 hours) Category: Wings
Clamped root rib to butt rib with 1/8 inch spacer. Measured distance to fuselage mounting bosses. Measured and cut standoffs. Drilled mounting to butt rib. Riveted standoffs to butt rib. Drilled and cut features into web for clearance of fitting s and fuel lines.
 
May 31, 2020     Aileron Leading Edge Splice - (1 hour)       Category: Wings
Aligned leading edge pieces, marked out spacing, drilled for 3/32nd holes. Matched drill splice doubler.. Countersunk for flush solid rivets. Installed rivets.

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May 31, 2020     Filler Rib Left Wing - (1 hour)       Category: Wings
Trimmed Filler rib caps flush with web aft edge. Taped wing trailing edge in place for filler rib alignment. Scuffed rear spar for bonding. Cleaned surface. Installed rib and confirmed position and squareness. Applied epoxy, let sit for 24 hours.

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May 30, 2020     Right Aileron Leading Edge Mod - (1 hour)       Category: Wings
Modified shape of leading edges of aileron ribs to fit custom shaped Steve Henry aileron leading edge.

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May 30, 2020     Butt Rib Fuel Tank Fuel Fitting Holes - (1.5 hours)       Category: Wings
Marked fitting locations to rib, drilled holes in rib to allow installation of fuel line fittings.

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May 29, 2020     Left Wing Root Rib - (2 hours)       Category: Wings
Fitted rib to spar, positioned similar to right wing. Abraded spars. Solvent cleaned. Epoxies in place.

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May 27, 2020     Fuel Tank Install Left Tank - (2 hours)       Category: Wings
Positioned butt rib so 1/8 inch gap with tank at ribs 1 and 2. Clamped 2 straight edges on underside. Positioned tank, clamped mounting brackets to tank and marked positions for attaching brackets to front and rear spars. Marked, drilled brackets, positioned and transferred drilled spars, riveted in place, applied epoxy at bracket spar joints.

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May 12, 2020     Right Wing Fuel Tank Cover - (2 hours)       Category: Wings
Drilled and located nutplates in trailing edge. Used strap duplicator to locate fuel tank cover mounting holes. Marked out and located fuel inlet.

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May 11, 2020     Right Wing Wing Tip Nutplates - (2 hours)       Category: Wings
Measured out, marked, drilled 1/8 center holes, checked, transferred drilled 3/32nd mounting holes, opened up center holes with #18, counter sunk 3/32nd holes. Riveted nut plates in place.

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May 10, 2020     Installed Left Wing - (1 hour) Category: Wings
Reamed fuselage mounts. Rearranged shop and located fuselage in other garage bay to make room for installing left wing.
 
Apr 28, 2020     Left Wing Tip Trimming - (1 hour)       Category: Wings
Applied tape along scribe line, used angle grinder with cutting wheel to trim part. Finished edge with hand sander. Sanders flash off at parting line as well.

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Apr 26, 2020     Right Wing Butt Rib - (3 hours)       Category: Wings
Pivoted wing back to place butt rib. Reamed tubing mounts on fuselage. Cut to length rib T-fittings. Clamped Butt rib to root rib, marked and located fuel fitting holes and sight gauge holes.

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Apr 25, 2020     Rib 9 Nutplates for Wing Tips - (2.5 hours)       Category: Wings
Located, marked, drilled, countersinked, riveted 23 nutplates into last rib of left wing.

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Apr 25, 2020     Epoxy Varnish Category: Wings
Ev-400 Epoxy Varnish kit Qt.
 
Apr 24, 2020     Right Wing Tank Nutplate Mounted - (1 hour)       Category: Wings
Located Nutplates with clecos to 4 drilled mounting holes. Transferred drill 3/32nd holes. Countersinked. Mounted nutplates with rivets, 4 places.

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Apr 24, 2020     Tank Cover Front Mount Nutplates - (2 hours)       Category: Wings
Installed nutplates to the two wing tank front mounts. Used 3 inch spacing. Drilled 1/8 holes on centers. Cleco'd nutplates to locate mounting holes, drill 3/32nd holes. Opened up 1/8 holes with #18 drill for thru holes. Riveted in place with solid rivets.

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Apr 23, 2020     Left Root Rib Nutplate Install - (1 hour)       Category: Wings
Marked Out Three Inch spacing. Drilled 1/8 inch holes on center. Cleco'd nutplates to locate 3/32nd holes. Drilled out 1/8th holes with #18 hole. Countersink rivet holes. Located rivets and squeezed to locate nut plates.

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Apr 21, 2020     Butt Rib Reinforcement - (2 hours)       Category: Wings
Steve Henry recommended improvement-adding reinforcement to the butt rib rib cap. The cap is stapled and glued to the web. The windshield is mounted to this rib. Fabricated aluminum angle extrusion to follow contour of upper rib cap. Will be epoxies and riveted in place.

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Apr 20, 2020     Left Wing-Installed Wing Joint Doublers - (1 hour)       Category: Wings
Match drilled doublers to spars. Abraded mating surfaces, cleaned surfaces with acetone. Epoxied, bolted and riveted in place. Cleaned surfaces of excess.

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Apr 19, 2020     Left Wing-Strut Brackets - (1.5 hours)       Category: Wings
Bonded previously drilled spar/lift strut brackets, interface front and rear spars. Installed Jury strut brackets. Cleaned and abraded surfaces, applied epoxy to both sides and rivet in place.

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Apr 18, 2020     Flight Test Manual and check cards Category: Wings
Ordered EAA's Flight Test manual and test check cards.
 
Apr 18, 2020     Lift Strut Brackets- Left Wing. - (1.5 hours)       Category: Wings
Drilled front and rear spar of left wing for lift strut brackets.

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Apr 16, 2020     Fuel Tank Cover Nutplates - (3 hours)       Category: Wings
Chalked lined on upper rib caps. Drilled 1/8 inch holes on ribs 1 & 2 every 3 inches. Cleco'd nutplates in place to locate 3/32nd mounting holes. Drilled holes. Cleaned surfaces. Countersink 3/32nd rivet holes. Cleco'd nutplates into position, installed flush solid rivets, used rivet squeezer to compress rivets to secure nutplates.

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Apr 15, 2020     Right Wing Tank Rib - (1 hour)       Category: Wings
Cut rib caps flush for trailing edge. Marked location on rear spar. Abraded spar surface, solvent cleaned. Applied epoxy, positioned end rib behind fuel tank. Used trailing edge to secure in place.

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Apr 15, 2020     Left Wing Stringer Install - (1 hour)       Category: Wings
Install stringer through ribs 2 to 9, mark where to cut to length. Abrade stringer for bonding to each rib. Clean surface with acetone. Position stringer. Apply epoxy.

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Apr 14, 2020     End Rib Drag Links - (2 hours)       Category: Wings
Fabricated drag links from leftover stringer material. Cut to length, pinched ends, bent angles, drilled mounting holes, transferred holes to rib and spar, drilled holes, abraded metal mating surfaces, applied epoxy and rivet in place.

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Apr 12, 2020     Left Wing Gussets - (1.5 hours)       Category: Wings
Positioned wing to work. Sanded mating surfaces. Applied epoxy to gussets, positioned. Applied epoxy fillets to both sides of 8 gussets between spars and drag links.

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Apr 12, 2020     Bonding Root Rib - (1 hour)       Category: Wings
Abraded spars, used acetone to clean up surfaces. Assured proper place and position of root rib. Epoxy rib in place.

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Apr 12, 2020     Root Rib Cutouts - (1 hour)       Category: Wings
Marked locations for fuel tank fittings locations onto root rib. Used hole saw to make holes.

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Apr 11, 2020     Ailerons Trailing Edge - (2 hours)       Category: Wings
Prepared trailing edge pieces for flaps. Cut to length, abrade mating areas, temp install for drilling mounting holes,#40, through rib caps, both sides. Countersink for 3/32 rivets. Mix up epoxy, apply to rib caps, install trailing edge, install rivets, wipe off squeeze out epoxy. Cure for 24 hours.

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Apr 10, 2020     Flaps - (2 hours)       Category: Wings
Prepared trailing edge pieces for flaps. Cut to length, abrade mating areas, temp install for drilling mounting holes,#40, through rib caps, both sides. Countersink for 3/32 rivets. Mix up epoxy, apply to rib caps, install trailing edge, install rivets, wipe off squeeze out epoxy. Cure for 24 hours.

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Apr 07, 2020     Fuel Tank Install - (1 hour)       Category: Wings
After brackets were installed, placed tank and drilled mounting holes in each of the four brackets. Shimmed with thick tape where needed to eliminate and play at mating surfaces.

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Apr 06, 2020     Fuel tank support brackets - (2 hours)       Category: Wings
Right Wing: Placed temp supports across underside of ribs #1 & #2. Positioned tank, clamped mounting brackets to mounts on fuel tank. Marked positions on front and rear spars. Removed tank, marked out 4 hole positions on each bracket, drilled #30 holes. Relocated brackets and drilled holes into spars. Riveted in place and backfilled with epoxy.

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Apr 05, 2020     Flap Trailing Edges - (2 hours) Category: Wings
Cut trailing edge material to length. Filed edges smooth. Installed onto flap ribs, marked on edge width of rib caps, both sides. Center punch for drilling #40 hole on trailing edge on each rib cap. Drilled. Ordered 3/32nd countersink.
 
Apr 02, 2020     Installed Right Wing - (.5 hour)       Category: Wings
Temporarily installed right wing to locate fuel tank and root rib.

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Apr 02, 2020     Trim Trailing Edge Rib Cap Strips - (1 hour)       Category: Wings
Trim and sand upper and lower cap strips at trailing edge flush with ribs. Radius edges so trailing edge installs flush.

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Apr 01, 2020     Lift Strut Wing Brackets - (2.5 hours)       Category: Wings
Lift Strut locations preset by factory. Aligned and match drilled bracket hole locations into front and rear spar of right wing. Cleco'd has holes were drilled. Removed, cleaned holes, painted brackets, abraded mating surfaces, mixed up epoxy, applied to mating surfaces, riveted in place and cleaned up epoxy squeeze out.

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Mar 30, 2020     Jury Strut Brackets, Right Wing - (1 hour)       Category: Wings
Measured and positioned jury brackets 90 degrees normal to bottom of front and rear spars. Drilled 1/8 holes in brackets teamed 3/16ths holes in tabs, abraded mating surfaces applied epoxy. Riveted in place. Cleaned excess squeeze out.

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Mar 28, 2020     Wing Tip Rib Drag Links - (1.5 hours)       Category: Wings
Fabricated drag links from leftover stringer material. Drilled for rivets. Abraded mating surfaces. Mixed up Hysol and applied to cleaned mating surfaces. Installed rivets. Cure for 24 hours.

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Mar 28, 2020     Attachment Doubler - (2 hours)       Category: Wings
Installed upper and lower doubles to forward and aft spar fuselage attachment points for right wing. Located, drilled #30 holes 4 places per doubler. Mixed up Hysol epoxy, abraded mating surfaces. Cleaned, applied Hysol to mating surfaces. Installed rivets and fastener. Let cure 24 hours.

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Mar 25, 2020     Gussets - (2 hours)       Category: Wings
Installed gussets between drag links and spars on right wing. Shaped gussets to fit. Roughed up surfaces on drag links and spars where gussets install. Applied Hysol to edges of gussets and installed eight places. Then applied Hysol fillets to all sides of install.

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