EAA Builders Log Site

Project: Voltar-S21 -
Listing for Category : wings

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Categories

Show All Entries - (825)
Research - (9)
Workshop - (16)
Empennage - (4)
Fuselage - (175)
Firewall - (19)
Tail Feathers - (70)
Wings - (190)
Controls - (9)
Avionics - (105)
Lighting - (3)
Instrument Panel - (72)
Landing Gear - (11)
Engine - (93)
Propeller - (5)
Fuel System - (6)
Interior Finish - (35)
Paint / Decals
Inspection - (2)
Tools
Suggestions - (1)


Builder Name:	Vern Little -

Project:	Rans - S-21 Outbound - VIEW REPORTS
Total Hours:	2310.8
Start/Last Date:	Mar 06, 2018 - No Finish Date

Friendly URL:	https://eaabuilderslog.org?s=Voltar-S21

Home or Last Project Picture

Nov 23, 2023 Wingtip Repair - (3.2 hours)

Category: Wings

Cleaned up shop and worked on wingtip repairs. Used scrap PVC cuttings and bonded a doubler in place, followed by the finished layer. Will fill gaps with epoxy plastic glue.

Pause in construction now. The homestretch is pending.

Wingtip Repair

Doubler Primed

Home Stretch

Nov 15, 2023 Tinnermans - (3.5 hours) Category: Wings

Put all the wing tinnermans in place and tidied up pitch trim wiring. Organized tools and cleaned up.

Nov 14, 2023 Rigging - (3.5 hours)

Category: Wings

Completed rigging of ailerons and flaps, except for safety wiring the turnbuckles. Turns out the flaps were the most difficult, with four ball end bearings to adjust. It has to be done just so, or the Teleflex cable can interfere with the bellcrank. For example the right and left Teleflex cable needs to rigged slightly differently at the flap handle to avoid this interference in my kit.

Dialed in the correct deflection for the surfaces, torqued everything and marked with laquer.

Made a special wrench to fit through the cutout in the rear spar. This allows tightening the jam nut on the flaps pushrod.

With Flaps Position Sensor

Jam Nut Wrench

Flaps Rigging

Nov 13, 2023 Rigging - (4.7 hours) Category: Wings

Rigged aileron cables, tensioned cables and set control stops: Backed off turnbuckles, put 1/4” pins in bellcrank control locks, then tensioned the two main control cables with the sticks centered. Then, tensioned the crossover cable. Set the control stops by checking for proper aileron deflections on both sides.

Also installed the flaps teleflex cables. One of the rod end bearings interfered with the structure of the flap control assembly, so I disassembled it and offset the flap handle with a 1/16” washer. Need to adjust the flaps position at the clevis end on the wing. It is easier to make adjustments at the clevises rather on the flap handle assembly.

Nov 12, 2023 Rigging Ailerons - (3.0 hours) Category: Wings

Ran control cables for ailerons and attached turnbuckles. Did a prelinary rigging to ensure everything operates freely.

Nov 11, 2023 Wing Strut - (2.3 hours) Category: Wings

Detached right wing strut to allow for the riveting of the forgotten lift strut exit exit doubler ring (oops!). Also began rigging of right wing aileron cables.

Nov 10, 2023 Ailerons and Flaps - (2.5 hours)

Category: Wings

Completed rigging of ailerons and flaps, except for final torquing of fasteners. Binding of right aileron was found to be a rod-end bearing that required lubrication. Using LPS-2, lubricated all of the bearings in the flaps and aileron linkages, plush the hinge bushings. Cut gap seal on left wing to allow bolt tail on flap clevis to clear.

L Flap Hinge

Flaps and Ailerons

R Flap Hinge

Nov 09, 2023 R Aileron & Flaps - (4.5 hours) Category: Wings

Attaching R aileron and flaps. Fabricated aileron pushrod bushing and attached aileron. Needed to peen gap seal for rivet heads. Also, I remove the aileron and squeezed the gap fairing with my hands to prevent skin binding. Reinstalled, but have another problem with the bellcrank binding.

Made relief cut in right wing gap seal to allow for the tail of the flap clevis attachment bolts to clear. Used my rotary cutter with a HSS cutting bit.

Nov 08, 2023 L Aileron and Flap - (2 hours)

Category: Wings

Rigging L Aileron and Flap. Removed aileron and slightly enlarged slot in gap seal and rear spar. This insures that the control stick aileron stop will limit the movment and prevent the aileron pushrod from contacting the spar in full down position. Reattached.

Peened the gap seal over the Flap to prevent rivet contact when fully retracted

Aileron Pushrod

Nov 07, 2023 Rigging L Aileron - (2 hours) Category: Wings

Working on attaching left aileron to bellcrank. Conflicting plans, so I have chosen to shorten the bushing and follow the new plans. Some rivet heads were interfering with flap gap seal, so I peened the fairing to allow clearance.

Nov 05, 2023 Left Aileron - (1.5 hours) Category: Wings

Worked on attachment of left aileron. Couldn't find a long 1/4 inch bolt to lock the turnbuckle, so used a the shaft of a 12” 1/4” drill instead.

Oct 23, 2023 L Wing Torquing - (1.5 hours) Category: Wings

Drilled extra AN3 bolt for aft spar attach, and torqued all wing and strut atachment bolts.

Oct 21, 2023 L Wing Attachment - (5.5 hours)

Category: Wings

Attached left wing, with assistance from Rob. Draped hinges with rags to help prevent cranial damage. Includes 2.0 hrs for Rob.
Also used cyanoacrylate glue to tack VS bottom edge moulding in place. Ensured the moulding is pressed as far up as possible before tacking it with the glue— installing the VS is easier that way! Just tacked it in a few places— the moulding is captured when the VS is bolted in place.

Wings On

Oct 18, 2023 Wing Attach - (2.5 hours)

Category: Wings

Torqued L wing spar attachment bolts. Drilled for extra AN3 bolt in aft spar attachment. Attached two cover plates on L wing, just see the result. Apparently I didn't order any fairings to cover the strut-wing attachment.

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Oct 17, 2023 L Wing Attachment - (3.2 hours)

Category: Wings

Prepped the left wing for attachment: trimmed forward left fuselage T-bone, match drilled truss attach fittings and up drilled 7/16” spar bolt attachment to truss fittings. Loosely remounted fittings to wing. Upsized forward wing spar attachment holes to 3/8”, by progressively upsizing the holes and finishing with a 3/8” reamer. Rounded strut-fuselage attach fitting to clear the welds on the fuselage fork.

Rounding Strut to Fuse

L T-Bone

Truss Fittings

Oct 16, 2023 Securing Bolts - (4.0 hours)

Category: Wings

Torqued all strut bolts and tightened R wing root bolts (they will be torqued later). Had to R&R aft root bolt to add missing washer. Cleaned shop, getting ready for L wing attachment. Actual install will be on the weekend when my helper is available.

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Oct 15, 2023 Right Wing Mounting - (8.0 hours)

Category: Wings

Prepared R wing for mounting and hung onto fuselage. Required a lot of careful drilling, alignment and fussing. Rob P 4.0 hrs. The stand I made worked perfectly to support one end of the wing, allowing the two of us to focus on the task of attaching the wing-fuselage interface bolts.

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Rob

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Oct 14, 2023 R Wing - (4.5 hours) Category: Wings

Prepped R wing for installation: wet riveted inspection plate doubler rings in place with CCC-42 (flush) rivets. Carefully measured, then used die grinder/cutting disc to trim R T-bone attachment and primered cut surfaces. 1.0 hrs assitance from R. Prior.

Oct 09, 2023 Wing Stand - (2.0 hours)

Category: Wings

Fabricated an adjustable wing support stand to assist in installation. Used screws, hinges and scrap lumber for structure. Cut a shop pad up to form the padded cross-piece and attached the pieces with staples.

Wing Stand

Dec 08, 2022 Sealing Fuel Filler - (2 hours)

Category: Wings

Scotch-brited and cleaned around filler cap, prosealed fuel filler to top skin, right wing. Taped off opening, trimmed with razor knife, then slathered on proseal. Tooled with a wet finger, then carefully pulled off tape.

Mess ‘O Tape

Proseal Fillet

Razor Cut

Dec 07, 2022 Connected Pitot/AOA - (4.0 hours)

Category: Wings

Connected pitot and aoa tubes and wiring to pitot/aoa probe Riveted the inspection panel rings onto the left wing. Reinstalled repaired Skyview and tested installation. Deburred rudder return assembly parts.

Pitot/AOA Connection

Left Wing Fully Riveted

Dec 06, 2022 Left Wing Strobe Light - (4 hours)

Category: Wings

Installed left wing strobe light onto wingtip and wired to 4-pin connector. Completed riveting of right wing landing light brackets. Touched up primer.

Left Wing Wiring

Dec 05, 2022 Strobe Wiring - (4.0 hours)

Category: Wings

Completed strobe wiring on right wing and started on left wing strobe wiring.

Right Strobe 1

Right Strobe 2

Dec 04, 2022 Landing Light - (3.5 hours)

Category: Wings

Completed most if the installation and wiring of right wing landing light. Still need to rivet the mounting brackets in place.

Right Wing Light

Dec 04, 2022 Right Wing Landing Light - (2.5 hours) Category: Wings

Stowed left wing on stand and put right wing on workbench. Cut opening for right wing landing light.

Dec 02, 2022 Landing Light - (3 hours)

Category: Wings

Wired the L wing landing light. Used Molex UML connector. Terminated all 5 wires, but just using two (power and ground). The ground is local (on a rib).

I do Wig-Wag with my own controller and a pair of relays. This allows me to have light switches that are up for ON, down for OFF and center for WIGWAG (flash).

Light Wiring

Left Light

Ground and Wiring

Wig-Wag Switches

Dec 01, 2022 Wing Riveting - (2.5 hours)

Category: Wings

For L wing: Riveted fuel tank supports in place. Riveted landing light brakes in place.

For R wing: Riveted fuel tank supports in place.

I used teflon tape as the ‘anti-chafe' tape called out in the SB.

Fuel Tank Support

Nov 30, 2022 Wing Riveting - (3.5 hours)

Category: Wings

Completed all of the rib riveting on the R wing. Primed tank AD parts and landing light brackets.

R Wing Riveted

Nov 29, 2022 Wing Riveting - (3.5 hours)

Category: Wings

Riveted right wing, except for tip and root ribs. Primed landing light mount and fuel tank AD parts with Super-K and a foam roller.

R Wing

Primed with Roller

Nov 28, 2022 Wing Riveting - (3 hours)

Category: Wings

Completed L wing riveting except for inspection panel rings, fuel tank AD and landing light bracket.

Left Wing Done

Nov 26, 2022 Closing Wing - (3.5 hours) Category: Wings

Riveted L wing bottom skin in place. Dipped rivets in Super-K. I had left the wing partially unriveted for inspection by MDRA.

The inspection panel rings will be left unriveted for now, for easier access. I have large hands, so this is easier for me.

Nov 25, 2022 Landing Light - (3 hours)

Category: Wings

Cut wing spar, trimmed lens and drilled for LED light mount in left wing. Riveting will await priming of parts.

Note on trimming the landing light lens: It's really easy to overtrim the lens so that it doesn't fit properly. I'd recommend making a template out of a piece of stiff cardboard (cereal box material) first and trimming it to a tight, conformal fit. I over-trimmed my first lens by about 1/4" so it no longer snapped tightly into place. The second one was perfect-- so tight that I had to release it using a paint stir-stick to pry it off the rivet tails.

To fix the first one, I bonded on a cutting of Lexan using Krazy glue and clamped it for 24 hours. That gave me the 1/4" back and the lens now snaps securely in place.

Internal Mounting

AeroLEDs Lamp

Nov 24, 2022 Pitot Wiring and Landing Light - (1 hour)

Category: Wings

Completed pitot wiring in left wing and laid out landing light cut template.

Light Cutout Marked

Nov 23, 2022 Tank AD - (4 hours)

Category: Wings

Attached pitot tube. Fabricated fuel tank retainer (Rans AD) for left wing. Had to trim outboard end of rear plate to clear a rivet tail from gap seal attachment.

The retainer is pretty clever. Designed to retrofit easily and two plates provide some flex to accommodate tank growth or shifting. Instructions kind of sparse, but OK.

Tank Retainer

Nov 23, 2022 Pitot/AoA - (3.5 hours)

Category: Wings

Mounted the pitot controller behind the pitot mast. This required R&R of the pitot mast for fine tuning of the mounting. Drilled and countersunk the pitot mast and pitot tube assembly for #40 stainless screws. The position of the drill holes is determined by the 'meaty' part of the pitot tube assembly.

Managed to break my #40 tap during the process, but dug it out of the pitot by cutting some of the RTV encapsulation.

Pitot Mast

Nov 21, 2022 Pitot AoA install - (3 hours) Category: Wings

Working on the plumbing and wiring for the heated pitot/aoa. Located the controller behind the mast. Attached the nuts and ferrules to the 3/16 probe and 1/4 inch main tubing.

Jul 18, 2022 Replacement Wing Struts - (2 hours)

Category: Wings

Riveting doublers onto new wing struts and drilling attachment holes to 7/16. Photo shows the new struts on the left alongside the old ones on the right.

The new struts have a different profile, so are resistant to the in-flight vibration of the old struts. In my case the old struts were misdrilled from the factory, so I implemented the service bulletin and upsized the rivets to 1/4". I takes a large 'bolt cutter' sized rivet puller to set 1/4" SS rivets!

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Jul 13, 2022 Primed Wing Struts - (3.2 hours)

Category: Wings

Primed the interior of the new wing struts. First cleaned with my custom degreaser and ‘Scotchbrite on a Stick' for the center section. Messy job.

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Aug 31, 2021 Panel - (2.2 hours) Category: Wings

More panel wiring.

Aug 30, 2021 Panel - (4.5 hours) Category: Wings

Panel wiring.

Aug 30, 2021 Pitot-AOA-Static

Category: Wings

Design of the main pitot-static-aoa system

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Jun 24, 2021 Aileron Balancing and Roll Servo - (3.7 hours)

Category: Wings

Poured lead shot/epoxy/microballons slurry into aileron tubes and checked balance. I may have to pour more lead shot into opposite end of aileron tubes after paint. The instruction say to leave about 14" when injecting foam for pouring lead shot in root end of tube, but that's not enough.

Temporarily assembled roll servo on bracket to determine position of tray and bracket. I am using Dynon servos, they seem to fit well. I will need to purchase proper drilled-head attachment bolts. The instructions and parts seem to be more geared towards Garmin mounting.

Aileron lead shot counterweights with epoxy and microballoons

Roll servo rough-in

Dynon servo kits

Jun 23, 2021 Strut Doubler Drilling - (1.0 hour) Category: Wings

Drilling remainder of strut doubler holes.

Jun 21, 2021 Drilling Struts - (1.5 hours) Category: Wings

Continued drilling new struts/strut doublers

Jun 14, 2021 Ailerons and Struts - (2.5 hours)

Category: Wings

Fabricated two pivots from scrap to be used for aileron balancing and mounted them to my workbench using screws.

Squirted spray foam into aileron leading edge tube and determined required counterweight by hanging a bag of clecoes off a short wooden dowel pushed into leading edge tube. Weighed clecoes, came up with 1.9 kg. Now I will select an equivalent weight of lead shot, mix up an epoxy slurry and pour into place. Will use a longer length of the wooden dowel to pack the slurry in place.

Ailerons will be balanced slightly nose heavy to allow for adjustments later.

Started on the replacement struts. Marked hole centerline on struts, then match drilled struts to doublers. Slid doublers into place with a through-bolt, clecoed into place and enlarged holes to #12 for rivets.

Cleco weights for balancing

Aileron balance pivots

Jun 11, 2021 Completed flaps and ailerons - (2.0 hours)

Category: Wings

Finished final riveting on second flap. Started deburring and prepping of replacement struts.

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Jun 10, 2021 Final Riveting - (2.5 hours)

Category: Wings

Closed up second aileron and one flap.

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Jan 26, 2021 Strobe Lights - (2.5 hours)

Category: Wings

Spent an hour finalizing the strobe light mounting. Need to order some connectors from Digikey.

A large crate arrived with expensive parts!

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Jan 25, 2021 Attaching Nav/Position/Strobes - (3 hours)

Category: Wings

Fabricated backing plates for WAT Nav/Position/Strobes. The Rans supplied backing plates are set up for Aveo strobes. The WAT Orion strobes a quite a bit bigger (and heavier!), but fully FAA certified... and brighter. Best of all, I won them in a photo contest, using my Harmon Rocket.

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May 26, 2020 Completed installation of R wing tank and installed L wing tank into wing. - (3.5 hours)

Category: Wings

Needed to slightly reshape the openings in the root rib to accommodate the sight gauge fittings. Installed plastic sight gauge fuel lines onto both wings. Began deburring Rudder parts.

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May 25, 2020 Pressure testing R wing tank, installing in wing Category: Wings

Needed to reshape the openings in the root rib to accommodate the sight gauge fittings.

May 24, 2020 Bonding wing tank screws, pressure testing L wing tank - (2 hours)

Category: Wings

Used balloon on fuel pickup port, with quick drain valve on top sight gauge fitting and plug in bottom sight gauge fitting. Filled air into tank with short bursts from an air compresser blow gun to inflate balloon. Checked for leaks with soapy water and by observing balloon diameter over time.

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May 22, 2020 Bonding fuel cap on R wing tank - (2 hours)

Category: Wings

Bonding fuel cap on R wing tank. The screws must be torqued firmly to draw the fuel cap flange and the backing ring together tightly. The polysulphide adhesive will ooze slightly around the perimeter of the flange when done correctly.

I used a clamp over the vent position to assist.

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May 21, 2020 Drill and cutting R wing tank, installing fittings. - (3 hours) Category: Wings

Repeated marking and drilling process on R tank. Mistakenly drilled fuel vent pilot hole. Will block with screw for pressure testing.

May 20, 2020 Installing fittings and bonding fuel cap on L wing tank - (3 hours)

Category: Wings

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May 19, 2020 Drilling and cutting L wing tank - (2.5 hours)

Category: Wings

Drilled L tank for sight tube and cut 3" opening for fuel cap. Match drilled fuel caps, doubler ring and tank.

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May 16, 2020 Fitting fuel tanks to wings - (2.5 hours) Category: Wings

Replacement fuel tanks fit fine. Need to purchase 1" wood dowel.

May 15, 2020 Unpacking and inventory of fuse/tail kits - (2.5 hours) Category: Wings

May 14, 2020 Unpacking and inventory of fuse/tail kits - (3 hours) Category: Wings

May 13, 2020 Unpacking and inventory of fuse/tail kits - (2.5 hours) Category: Wings

May 12, 2020 Received fuselage and tail kits at my hangar. - (2 hours)

Category: Wings

Uncrated Fuselage frame. Also contained wheel, brakes, tires and miscellaneous tail parts plus new fuel tanks.

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Oct 11, 2019 Remove forward attach brackets on wing root ribs. - (1 hour)

Category: Wings

For better fit, these brackets need to riveted into position from the inside of the ribs, rather than the outside as the plans show. This reduces rib twist.

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Oct 04, 2019 Riveting doublers to struts. - (1.5 hours) Category: Wings

Wet riveted using 1/4" rivets. A lot of armstrong force required!

Oct 04, 2019 Prepared Struts for riveting. - (1 hour)

Category: Wings

Used AN4 bolts as temporary fasteners and AN5 through bolt in tangs to ensure alignment for riveting. AN4 bolts will be removed after other holes are riveted, then these holes will be riveted.

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Sep 19, 2019 Riveted pitot mast to skin and screwed pitot stiffener to rib. - (1 hour)

Category: Wings

Used screws for stiffener because I was unable to get rivet puller inside wing.

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Sep 17, 2019 Cut opening for pitot/aoa tube in left wing - (1 hour) Category: Wings

Position: flange adjacent to inboard rib and tip of cutout in line with centerline of inspection plate.

Sep 15, 2019 Ran wingtip wiring for nav/position/strobe lights. - (1 hour) Category: Wings

Sep 11, 2019 R&R of bellcrank attachment bolts - (2 hours) Category: Wings

Unsure if thread locker was used, so redid bolts with threadlocker, torqued and safety wired; both wings.

Aug 28, 2019 Priming Wingtips - (2 hours) Category: Wings

Dupont Grey DTM epoxy primer

Aug 27, 2019 Sanding fill in L wingtip. Adding more filler to refine. - (1 hour) Category: Wings

Cleaning, sanding, Scotch Briteing

Aug 20, 2019 Added filler to ripples in L wingtip - (1.6 hours) Category: Wings

Ripples caused by using popsicle sticks to wedge tip to rib when bonding together.

Aug 19, 2019 Refined fit of L wingtip, added platenuts and secured to wing. - (2 hours) Category: Wings

Minor divots in plastic due to gluing process. Need to find a compatible filler to smooth out

Aug 14, 2019 Trimmed L wing tip to fit wing, glued tip and rib together. - (2 hours) Category: Wings

Used popsicle sticks as a spacer to hold rib off of work bench, and clecoed rib to workbench to provide mechanical security. Glued tip and rib with ABC glue. Challenge will be to pop out clecoes!

Aug 13, 2019 Fit R wing tip assembly to wing. - (4 hours)

Category: Wings

Used newer plans that shows additional screw attachments and nutplate backing. Tried soft rivets for nutplates, but bought 3/32" rivets at Canadian Tire and redid. Carefully sanded tip edges to fit.

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Aug 12, 2019 Gluing R wing tip and rib - (2 hours) Category: Wings

Ripped apart previous assembly and reglued with ABS glue that has a longer working time, to get a better fit.

Aug 11, 2019 Gluing R wing tip and rib - (2 hours) Category: Wings

Used PVC glue and primer

Aug 09, 2019 Fabicating Wing Tip Glue jig. - (1 hour)

Category: Wings

Trimming rib and wingtip.

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Jul 05, 2019 Fabricating L Wingtip - (1 hour) Category: Wings

Trimming rib and wingtip.

Jul 04, 2019 Fabricating R Wingtip - (3 hours)

Category: Wings

Trimming rib and wingtip. Clamped trimmed rib to wingtip to support tip when marking trim line.

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Jul 01, 2019 Slotting skins around hinges in L wing. Temporarily attaching flaps and ailerons on both wings for storage - (1 hour) Category: Wings

Safety wired flaps and ailerons to prevent accidental damage. Wings complete and ready for inspection.

Jun 30, 2019 Mounting R wing into cradle. Slotting skins around hinges in L wing. - (2 hours) Category: Wings

Jun 29, 2019 Cleaning and organizing shop. Fabricating R wing stand. - (1 hour) Category: Wings

Jun 28, 2019 Complete L & R wing riveting. - (3 hours) Category: Wings

Complete L & R wing riveting except last few rows to allow for MDRA inspection. Added two rivets- one for flap hinge slot and one for aileron hinge slot.

Jun 27, 2019 R. Drilled trailing edge holes to #30. Extended hinge slots to trailing edge to allow skin to be peeled up for inspection. - (1.7 hours) Category: Wings

Jun 26, 2019 R-Riveted stiffener. Trued wing and cleco'd aft skin. Drilled trailing edge to #40. - (2.5 hours) Category: Wings

Jun 25, 2019 R-extended hinge slots to trailing edge. Riveted leading edge back to stiffener. - (3 hours) Category: Wings

Jun 20, 2019 R-Drilled leading edge holes to #30, deburred, dimpled and countersunk spar. Primered countersinks and wet riveted bottom skin to forward spar. - (3.5 hours)

Category: Wings

Received permission from RANS (Randy Schlitter) to extend skin slots around hinges all the way to the trailing edge. I also added reinforcement rivets where required.

Do this allows the wings to be partially assembled, and the bottom wing skin can be peeled up for inspection or wiring. This inspection is a requirement of the Canadian MD-RA who need to review your workmanship before closing your 'box sections'. These include the wings, flaps, ailerons, VS, HS, rudder, elevator, and trim tab.

An unexpected side effect is that future internal modifications or repairs are also easier.

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Jun 19, 2019 R-Primered relief notch in stiffener, aligned wing and drilled leading edge holes to #40. - (2.5 hours) Category: Wings

Jun 17, 2019 Trimmed R bottom stiffener where it interferes with truss, R bottom dimpled skin and ribs for first 6 rows of flush rivets. Worked out two skin smilies. - (2.5 hours) Category: Wings

Jun 12, 2019 Leveled R wing on jigs. - (1.5 hours) Category: Wings

Jun 11, 2019 Flipped R wing and attached to jigs. Unrolled R bottom skin in preparation for dimpling. - (2 hours) Category: Wings

May 28, 2019 Completed riveting top R skin. - (1 hour) Category: Wings

May 27, 2019 Drilling aft spar and riveting top R skin - (3.3 hours) Category: Wings

May 24, 2019 Riveting top R skin - (0.8 hour) Category: Wings

May 23, 2019 Riveting top R skin - (2.5 hours) Category: Wings

May 21, 2019 Countersinking leading edge and Riveting top R skin. - (2.5 hours) Category: Wings

May 19, 2019 Truing R wing and preparing for mounting top skin. Rigging aileron and flap teleflex. Trimming stiffeners. - (1.5 hours) Category: Wings

May 09, 2019 Truing R wing and preparing for mounting top skin. Rigging aileron and flap teleflex. Trimming stiffeners. - (1.5 hours) Category: Wings

May 08, 2019 Dimpling top R skin and associated ribs. Mounting top skin and drilling leading edge. Riveting inboard rib and flap hinges with doublers. - (2 hours) Category: Wings

Used solid rivets on inboard rib hinges and doublers.

May 08, 2019 Installing R aileron and flaps bellcranks. Category: Wings

Short one AN4H-5 bolt, but had one spare AN4H-6. Realized that completed L wing may have used a wrong bolt. Removed and replaced L wing AN4H-6 with proper AN4H-5 and completed R wing flaps bellcrank with correct bolts.

May 07, 2019 Riveting R wing ribs to spars - (2 hours) Category: Wings

May 06, 2019 Riveting flap and aileron hinges, bellcrank doubler and flaps teleflex support to ribs. - (2.5 hours) Category: Wings

Apr 30, 2019 Straightening R wing ribs, attaching to forward and aft spars. Bolting on aft spar. - (3 hours) Category: Wings

Needed slightly longer (-17) bolts for rear truss attach, plus 3 x AN960-416 spacer washers.

Apr 26, 2019 Bolting Truss onto D-Spar - (4 hours) Category: Wings

Forgot some washers, had to do it twice. Trick is to bolt and torque the two bolts nearest the truss axis first, then the the outside two.

Apr 25, 2019 Trimmed R D-spar to be flush with tip rib. Attached truss to R D-spar. - (3 hours) Category: Wings

Needed to buy longer 1/2 wrench to reach into spar.

Apr 24, 2019 Modified L& R root flap hing for fuel tank feed - (2 hours) Category: Wings

Using modification kit from Rans. Modified root rib, flap bracket and attached doubler.

Apr 23, 2019 Modified L root flap hing for fuel tank feed - (1 hour)

Category: Wings

Using modification kit from Rans. Modified root rib, flap bracket and attached doubler.

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Dec 19, 2018 LW. Attached bottom skin with tack rivets (temporary rivets). Drilled and deburred aft skin/spar attachment. - (3 hours) Category: Wings

Preparing wing for storage. Using all aluminum tack rivets that will be drilled out later for inspection.

Dec 18, 2018 LW. Completed drilling skin/spar attach, countersunk spar and wet riveted skin to spar. Fabricated rivet shear test rig. - (3 hours)

Category: Wings

Tested AAPQ-41 and CCC-42 rivets in shear by mounting test coupon to scissor jack. AAPQ failed quickly and blew off, CCC deformed but remained in place. CCC dimple deformed and torn.

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Dec 15, 2018 LW. Drilled forward row of skin/spar holes. Category: Wings

LW. Drilled forward row of skin/spar holes. Primered around strut opening reinforcement plate. Primered stiffener where relieved to clear truss weldment.

Dec 14, 2018 LW. Dimpled ribs and clecoed skin in place. - (3 hours) Category: Wings

Filed around tie-down slot and one hinge bracket to ensure skin clearance.

Dec 13, 2018 LW. Rivets arrived from ACS. Completed riveting of ribs and doublers on L Wing, and dimpled L bottom skin. - (3.5 hours) Category: Wings

Misdimpled aft part of skin instead of leading edge. Flattened the wrong dimples and dimpled first 6 rows of #30 holes on leading edge.

Dec 05, 2018 LW. Cleaning and reorganizing shop. - (2 hours) Category: Wings

Moved workbenches and relevelled wing. Trial fit fuel tanks��too fat, need new tanks or modified stringers.

Dec 03, 2018 LW. Flipped wing and aligned to table. Trimmed stiffener to length. - (3 hours)

Category: Wings

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Dec 01, 2018 LW. Priming edge of gap seal under top skin and aft priming spar covered by gap seal. Completed riveting. - (4.5 hours) Category: Wings

Still awaiting rivets to complete two holes on truss doubler.

Nov 30, 2018 LW. Drilling and deburring aft spar. Bending flap/aileron gap seal. - (3.5 hours) Category: Wings

Nov 29, 2018 LW. Riveting ribs and stiffeners - (3 hours) Category: Wings

Nov 28, 2018 LW. Riveted 6 rows of rivets with CCC-42 . - (2.5 hours) Category: Wings

Nov 27, 2018 LW. Removed skin to complete dimpling on skin and ribs. Reattached skin and riveted first row of rivets along spar. - (4.5 hours) Category: Wings

Put a large smiley in skin during handling. Worked out with a large spoon.

Nov 26, 2018 LW. Trimmed front end of rib flanges to prevent interference with spar. Drilled and countersunk D spar, dimpled skins - (4 hours) Category: Wings

The plans show just one row of countersunk rivets along D spar. I plan on 4-6 rows of countersunk rivets between spar and first stiffener.

Nov 24, 2018 Routed wing tip wiring and wing stiffeners. - (4 hours) Category: Wings

Leveled and trued wing structure. Trimmed L wing stiffeners to 116 7/8". Inserted wing stiffeners and clecoed top wing skin in place. Plans don't indicate stiffener length. Estimated 117", but needed to trim 1/8" of outboard end to allow holes to line up.

Nov 23, 2018 Routed Pitot and AoA lines in L wing. - (3.5 hours) Category: Wings

Use aluminum tubing.

Nov 22, 2018 Rigging L aileron cables and flaps Teleflex cable, some riveting. - (3.5 hours) Category: Wings

Replaced aileron cable guide with new version and reversed bearing attach bolts to prevent cable interference and simplify inspection. Drilled ribs and inserted snap bushings for wiring and bonded grommet strips to inside wing rib openings.

Nov 21, 2018 Assembled L wing frame and riveted aft ribs into place. - (3.5 hours) Category: Wings

Drilled out a few rivets that were supposed to be left out until gap seal assembled.

Nov 20, 2018 Riveted L hinges, aileron and flaps bellcrank mounts and flaps telefex mounts onto ribs. - (3.5 hours) Category: Wings

Nov 19, 2018 Straightening L wing ribs, assembling flap and aileron hinges. Bolted Truss to aft spar. - (2.5 hours) Category: Wings

Noticed that the inboard flap hinge that I have is not the same as the current documentation. The new rib has an oval hole cutout for the fuel line fitting. Need to get new part.

Nov 17, 2018 Attaching L wing truss - (2.5 hours) Category: Wings

Bolted L wing truss to forward spar. Everything fit, but bolts are difficult to get into position. Used a mirror and a flashlight positioned opposite of the end where I had to reach in to insert/attach nuts and bolts. A paint stick with a 1/2" hole serviced to hold bolts and nuts and reach into spar.

Nov 16, 2018 Assembling Flaps bellcranks and mounting strut attach brackets - (3.5 hours) Category: Wings

Completed L and R flaps bellcranks. Match drilled L Strut attach brackets and bolted to truss.

Nov 15, 2018 Assembling aileron bellcranks. - (2.5 hours) Category: Wings

Completed L and R aileron bellcranks

Nov 14, 2018 Assembling wing spars, assembling aft spar wing root attachment brackets. - (2.5 hours) Category: Wings

Rivet R aft spar doubler. Bevelled edges of aft spar attach doublers to sit flush on spar webs, attached aft spar attach fitting and shims by tapping shims into place with a hammer and wooden stir stick.

Nov 13, 2018 Cleaning shop and assembling L wing spars. - (2.5 hours) Category: Wings

Riveted L aft spar doubler. Filed spar flush with tip rib. Brushed primer on aft side of aft spars where root doubler mounts. Reamed out L spar truss attachment holes to 5/16" oversize to remove paint and burrs.

Nov 09, 2018 Priming Wing ribs. - (3 hours)

Category: Wings

Primed with Super-K.

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Nov 08, 2018 Priming Wing ribs. - (2.5 hours) Category: Wings

Primed with Super-K.

Nov 07, 2018 Cleaning Wing ribs. - (3 hours) Category: Wings

Cross-scrubbed with Scotch Brite and PreKote. About 15 minutes per wing rib.

Nov 06, 2018 Priming wing spars, gap seal and stiffeners. - (3 hours) Category: Wings

Touched up main spars and primed where skin overlaps spar skirts. Primed aft spars and wing stiffeners.

Nov 05, 2018 Cleaning aft spars, flap gap seals, stiffeners and main spars - (2.5 hours) Category: Wings

Prepping for priming.

Nov 02, 2018 Assembling wing spars, cleaning and priming struts - (3 hours) Category: Wings

Riveted leading edge doublers to spars. Cleaning with PreKote and primed interior of lift struts with Super Koropan.

Oct 31, 2018 Assembling wing spars - (2 hours) Category: Wings

Continued removing tape residue removed with MEK and wool scrubbing pad. Wet riveted D spar doublers to spar web.

Oct 30, 2018 Priming wing spars - (4.5 hours)

Category: Wings

Sealed all openings, rivet holes and one end with clear Gorilla tape. Poured 4 oz. 10% MEK thinned Super Koropan primer into spar cavities. Tilted and rotated spar to ensure throrough internal coverage. Drained excess, let set up, then stripped tape. Primer leaks and tape residue removed with MEK and wool scrubbing pad.

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Oct 29, 2018 Preparing wing spars for priming. - (2.5 hours) Category: Wings

Preparing wing spars for priming.

Oct 28, 2018 Trial fitting wing spar doublers and strut components - (2.7 hours)

Category: Wings

Lift strut holes do not match internal doubler, some holes also oversize. Contacted Rans for resolution.
Update, after much arguing, Rans issued an Assembly Alert to resolve this problem. Required match drilling doublers and struts to 1/4" and using 1/4" SS rivets instead of the original 3/16" SS rivets. Problem resolve and strut is probably stronger than designed.

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Oct 26, 2018 Assembling and riveting R Flap. - (2.5 hours) Category: Wings

Completed flap riveting and leading edge spar drilling. Ready for inspection.

Oct 24, 2018 Assembling and riveting R Flap - (3.5 hours) Category: Wings

Bent trailing edges so that skin 'closed' at leading edge. Wet riveted and filled heads with primer.

Oct 20, 2018 Riveting R Aileron - (3.5 hours) Category: Wings

Bent trailing edge so that skin 'closed' at leading edge. Wet riveted and filled heads with primer.

Oct 19, 2018 Cleaning shop and assembling R aileron - (2 hours) Category: Wings

Oct 18, 2018 Assemblin L aileron - (2.5 hours) Category: Wings

Oct 17, 2018 Assemblin L aileron - (3 hours) Category: Wings

Oct 16, 2018 Shooting primer, wing parts - (2.3 hours) Category: Wings

Oct 15, 2018 Scrubbing wing parts with PreKote for priming - (3.5 hours) Category: Wings

Additional wing parts prepped.

Oct 14, 2018 Riveting Aileron - (2.7 hours)

Category: Wings

Fabricated trailing edge bending brake and attached to workbench.
Squeezed trailing edge of L aileron with bending brake to improve fit with ribs. Riveted bottom ribs to skin.

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Oct 12, 2018 Riveted Aileron and Flaps hinge-rib assemblies - (3.5 hours) Category: Wings

Short 8 AAPQ-62 rivets. Ordered from Rans. Wet riveted with Super-K and dabbed factory heads as well to fill pull stem cavity and rivet head.

Oct 11, 2018 Scrubbing wing parts with PreKote for priming - (5 hours) Category: Wings

Scrubbed and cross-scrubbed with PreKote and rinsed with copious amounts of water. Primed parts with Super Koropon.

Oct 10, 2018 Scrubbing wing parts with PreKote for priming. Priming parts. - (5 hours) Category: Wings

Scrubbed and cross-scrubbed with PreKote and rinsed with copious amounts of water. Primed parts with Super Koropon.

Oct 09, 2018 Scrubbing wing parts with PreKote for priming - (2 hours) Category: Wings

Used homebrew PreKote and Maroon Scotchbrite pad. Scrubbed and cross-scrubbed with PreKote and rinsed with copious amounts of water.

Jul 29, 2018 Priming wing skins. - (2.5 hours)

Category: Wings

Super Koropan primer

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Jul 28, 2018 Scrubbing wing skins for priming - (2.5 hours) Category: Wings

Used homebrew PreKote and Maroon Scotchbrite pad. Scrubbed and cross-scrubbed with PreKote and rinsed with copious amounts of water.

Jul 23, 2018 Wiping parts with Naptha, laying out on work benches in preparation for priming prep. - (3 hours) Category: Wings

Jul 16, 2018 Deburring replacement KPFL0166 - (1 hour) Category: Wings

Jul 10, 2018 Deburring Wing stiffener holes and replacement KPFL0166. - (1.5 hours) Category: Wings

Deburred flat side holes with 150 grit aluminum oxide sandpaper. KPFL0166 are replacement parts with concentric holes (originals were mis-drilled at factory)

Jun 30, 2018 Deburring Wing stiffener holes - (2 hours) Category: Wings

Deburred interior holes with drill bit.

Jun 21, 2018 Fabricated Sanding wand for interior of wing spars. - (1 hour)

Category: Wings

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Jun 12, 2018 Deburring flaps/aileron gap seal - (1 hour) Category: Wings

Jun 09, 2018 Deburring main spars. Category: Wings

Completed main spars, working on aft spars.

Jun 08, 2018 Deburring main spars. - (1 hour) Category: Wings

Received new aileron bellcrank pulley stand-off bushings and replacement KPAL0146-R aileron rib from Rans

Jun 04, 2018 Deburring bottom skin holes and main spars. - (1 hour) Category: Wings

May 30, 2018 Deburring bottom wing skin holes - (1 hour) Category: Wings

May 21, 2018 Nose rounding of flaps/aileron ribs and spar deburring. - (2 hours) Category: Wings

Filing tooling marks on spar cutouts.

May 19, 2018 Adjusting Action Ribs for smooth fit. - (1 hour)

Category: Wings

Ensured flanges at 90 degrees and that fingers on nose are 'rounded' in disc sander to ensure skins lie flat.

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May 15, 2018 Deburring bottom skins holes. - (1 hour) Category: Wings

Using a grey Scotch Brite disc.

May 14, 2018 Deburring bottom skins holes. - (1 hour) Category: Wings

Used grey Scotch brite disc.

May 13, 2018 Deburring bottom skins - (1 hour) Category: Wings

May 09, 2018 Completion of second wing rack. - (2 hours)

Category: Wings

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May 07, 2018 Building of second wing rack, deburring top skins. - (1.2 hours) Category: Wings

Inside of skins has aluminum manufacturer's printed information.

Apr 26, 2018 Completion of first wing rack, mounting of top skins. - (1 hour) Category: Wings

Apr 25, 2018 Inspecting for parts with non-complant edge distances in rivet holes - (1 hour)

Category: Wings

All flaps and aileron ribs, skins, several fittings and some wing parts non-conforming. Contacted Rans for resolution. Non a problem, kit was engineered with reduced edge distance.

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Apr 25, 2018 Construction of wing skin support frames - (2 hours)

Category: Wings

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Apr 24, 2018 Construction of wing skin support frames - (1 hour) Category: Wings

Construction of wing skin support frames

Apr 23, 2018 Construction of wing skin support frames - (2 hours)

Category: Wings

Frames will be mounted to wing dollies to facilitate storage and priming.

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Apr 22, 2018 Wing part deburring and inspection - (1.5 hours)

Category: Wings

Found crack in one of the KPAL0147-R ribs. Unrepairable, contacted Rans for a replacement.

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Mar 15, 2018 Wing ribs deburring and fluting.

Category: Wings

Found cracks in the KPWI0639 and KPWI0640 ribs. Dressed out relief notches to stop cracks from propagating.

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Mar 14, 2018 Wing ribs deburring and fluting. - (1.0 hour) Category: Wings

Mar 13, 2018 Flaps and wing parts deburring, filing. Fluting ribs - (2.5 hours) Category: Wings

Mar 12, 2018 Flaps and wing parts deburring, filing. - (2 hours) Category: Wings

Prepping and priming all wing parts prior to assembly.

Mar 11, 2018 Flaps and wing parts deburring, filing. - (2.5 hours) Category: Wings

Mar 10, 2018 Aileron and flaps parts deburring, filing. Tubular spar hole deburring. - (6.5 hours)

Category: Wings

Used EZ-Burr tool to deburr holes in flaps tubes. Excellent! This is an early kit, so some of the machining is less than perfect. Deburr and move on.

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Mar 09, 2018 Aileron and flaps parts deburring, filing Category: Wings

Mar 08, 2018 Aileron parts trimming, deburring, filing - (2.3 hours) Category: Wings

Mar 07, 2018 Uncrating - (3 hours) Category: Wings

Mar 06, 2018 Received Wing Kit

Category: Wings

Wing kit arrived, delivered by SeaWings at CYYJ, forwarded from Can Amer Freight, Blaine WA.
Voltar has laid an egg! Transfer cost $CDN 275.

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