Jul 13, 2020     Fitting wings       Category: Wings

Installed wings for the first time. On my previous build, this was one of the most challenging steps, with multiple fittings as the subspars were slowly filed to final size. This time was different. Although the spar pins were tight, they could be inserted without any filing or trimming of either the skins or subspars. Next the flaperons were clamped in position (each 1/8 inch down from wingtip). Pushrods were adjusted so the two flaperon tubes were in the correct position with control sticks fixed in the neutral position. Then the holes for fasteners completing the flaperon linkages were drilled. After this was completed, the wings were removed and placed in their rack pending final assembly. The tail cone was positioned to allow completion of connections with the fuselage. Thanks Tim for your help!

  Apr 04, 2020     Position light       Category: Wings

Cut and fitted fiberglass wing tip position light and strobe mount. Mounted light and completed all electrical connections. Final fiberglass work will be completed when the weather warms up. This completes the right wing.

Began unpacking the fuselage. Lots of paper, parts and hardware. hard to believe an entire fuselage is in that box!

  Apr 03, 2020     Wing tip       Category: Wings

Completed riveting of wing tip and mounted flaperon.

  Apr 02, 2020     Top wing skins and wing tip       Category: Wings

Completed riveting of top wing skins and began fitting wing tip skins. As with the landing light, the second time bending wing tip tabs, fitting and riveting skins was much faster.

  Apr 01, 2020     Landing light and top wing skins       Category: Wings

Installed landing light. Much easier the second time around. Began riveting top wing skins.

  Mar 31, 2020     Top wing skins and flaperon brackets       Category: Wings

Flipped wing right side up and pulled/clecoed leading edge skins into place. Partially riveted as per plans. Installed flaperon brackets.

  Mar 30, 2020     Bottom wing skins       Category: Wings

Fitted deburred, clecoed and riveted all bottom wing skins and wing skin doubler. Most rivets in a day!

  Mar 29, 2020     Wing ribs, wire harness and inboard lower skin       Category: Wings

Riveted nose ribs and stub spar. Installed right wing wire harness and mounted electrical connector in root rib. Prepped and clecoed inboard lower wing skin.

  Mar 27, 2020     Right wing ribs       Category: Wings

Riveted main ribs and rear spar to the right wing spar.

  Mar 26, 2020     Wing tip closeout and position light       Category: Wings

Bottom wing tip tabs were bent using a wooden tool (per plans) and digital protractor. The skin was then clecoed and riveted in place. Fit was remarkably good. The rear closeout panel was installed, completing the wing tip. The position light fiberglass bracket was cut to shape, drilled and clecoed to the wing tip. The position light was bolted to the fiberglass and all electrical connections completed. Final fiberglass work will wait for warmer weather.

This completes the left wing.

  Mar 25, 2020     Top wing skins and wing tip       Category: Wings

Completed riveting of top wing skins and began wing tip. Top wing tip skins were fitted and riveted in place. The bottom skins was marked with desired angles for each mounting tab.

  Mar 24, 2020     Top wing skins       Category: Wings

Continued riveting the top wing skins and wing walk doubler on inboard skin

  Mar 23, 2020     Landing light and top skins       Category: Wings

Completed landing light installation. Getting a tight fit for the lens was a challenge. I first cut the lens to almost final size. I then marked the top mount holes and drilled #30. These were then clecoed in place and bottom mount holes marked. The lens was removed and bottom holes drilled ~1/16"" behind the marks, pushing the lens forward for a very tight fit. Also began riveting the top wing skins.

  Mar 21, 2020     Landing light and flaperon brackets       Category: Wings

This was a good time to fit the landing light, as access was optimal. Flaperon brackets were also riveted in place.

  Mar 19, 2020     Top wing skins       Category: Wings

Flipped wing over and began fitting leading edge. It took a fair amount of pulling the skins tight over the ribs to get the holes to line up, but once completed, fit was excellent.

  Mar 16, 2020     Left lower wing skins       Category: Wings

Completed riveting of left lower outboard and middle wing skins. Installation is simple, but involves significant skin prep (mostly edges) and lots of rivets. Everything fit well. It's easy to see progress with such large pieces.

  Mar 16, 2020     Wing skin       Category: Wings

Completed riveting left lower inboard wing skin

  Mar 15, 2020     Wing assembly and initial skinning       Category: Wings

Added left wing wire harness including connection to stall warning microswitch. Mounted electrical connector on inboard rib. Orientation is critical and took some time to ensure correct. Added AOA tubing and port (similar to the static ports, the AOA port is a rivet with the mandrel removed). Began skinning with inboard lower skin. These pieces cover the entire bottom and wrap around to also cover the forward third of the wing. Five different types of rivets are used on this single piece. The wing skin doubler was also final drilled and riveted.

  Mar 14, 2020     Wing assembly       Category: Wings

Added stall warning microswitch and vane. Riveted nose ribs and leading edge stub spar assembly to main spar.

  Mar 13, 2020     Wing frame       Category: Wings

Attached main ribs and rear spar. Riveted rear spar doubler plate and flaperon hinge. Starting to look like a wing!

  Mar 12, 2020     Wing prep       Category: Wings

Continued wing prep. Removed select rib flanges per Kit Assembly Instructions (KAI). Final drilled flaperon attached bracket rivet holes to ribs

  Mar 08, 2020     Wing prep       Category: Wings

Fluted and deburred all nose and main ribs. There are a lot of ribs!

  Mar 07, 2020     Wing prep       Category: Wings

Assembled and riveted flaperon brackets. Straightened stub spar and countersunk leading edge rivet holes (oversize to accept skin). Added stub spar doubler

  Mar 03, 2020     Main spar preparation       Category: Wings

Continued main spar preparation adding rib mount and tip flanges

  Mar 02, 2020     Rib flanges       Category: Wings

Began main spar preparation adding rib attachment flanges and riveting spar. Most of the spar comes assembled and anodized. Flanges and spar completion only require use of pull rivets.

  Mar 01, 2020     Flaperons       Category: Wings

Framed, clecoed and riveted right flaperon.

  Feb 29, 2020     Flaperons       Category: Wings

Completed skinning of the left flaperon

  Feb 25, 2020     Faperons       Category: Wings

As with the empennage, no jigs are required to construct the flaperons. The predrilled holes allow for self alignment. Skinning the left flaperon.

  Feb 23, 2020     Flaperons       Category: Wings

To maximize use of my limited workspace, I decided to build the flaperons prior to the wings. Construction was similar to the rudder/stabilator except for the use of a stainless steel tube as a counterbalance. Non alclad parts were anodized, precut, drilled and tapped. This saved substantial time as the plans had these steps all performed by the builder. The additional prefabrication in the newer kits is greatly appreciated!

  Feb 21, 2020     Wing kit       Category: Wings

The wing kit finally arrived. Hard to believe these boxes contain all the parts for two wings!