Project: phowe   -  
            Listing for Category : wings
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Builder Name:Philip Howe   -  
Project:   Rans - S-21 Outbound   -   VIEW REPORTS
Total Hours:1654.75
Total Flight Time:6
Total Expense:N/A
Start/Last Date:Oct 19, 2020 - No Finish Date
Engine:Rotax 915is
Propeller:Whirlwind
Panel:Dynon
 
Friendly URL: https://eaabuilderslog.org?s=phowe

Home or Last Project Picture

May 06, 2024     Hung 1 Flap - (1 hour)       Category: Wings
Taylor and I hung one flap on the right wing. but needed to rig the ailerons before moving on to the flaps.


 
May 06, 2024     Temporary Hung Wing Tips - (1 hour)       Category: Wings
We hung both wingtips as they are required for aligning the ailerons for rigging.


 
May 03, 2024     Ailerons - (2.95 hours) Category: Wings
Mounted the ailerons on the wings.
 
May 01, 2024     Matched drilled Holes in T-Bone - (1.05 hours)       Category: Wings
We matched drilled the 3 holes in the rear T-Bone wing mount on the left and right wing.


 
May 01, 2024     Mounted Wings - (6 hours)       Category: Wings
We noticed that the front spar visible from the cockpit was only partially painted in orange. So we sanded and compromised by spray painting it black. We reviewed the installation procedures with three of us holding the wing Brenden then inserted the bolts, nuts, and washers into the wings and struts. The bolts were then torqued. The bolts were snug but not nearly an issue as last time. High Fives were exchanged.


 
Apr 30, 2024     Ailerons, Flaps and Wings - (2 hours)       Category: Wings
Attached the push-pull tubes to the ailerons and flaps in preparation for mounting the wing. We also located all the bolts, washers, and nuts and placed them in the freezer to make them slightly thinner as we had so much trouble when we test-mounted the wing several years ago.


 
Apr 29, 2024     Installed Return Fuel Fitting - (2 hours)       Category: Wings
We drilled and installed the new fitting in the left fuel tank for the return fuel from the header tank. This is needed for the 915is as it returns unused fuel to the header tank. This requires that there is the ability to return fuel to the fuel tank. We then pressure-tested the tank.


 
Apr 17, 2024     Wing Fuel Tank Brackets AD-142 - (4 hours)       Category: Wings
We prepared the brackets shipped to me by Rans. We then measured and match-drilled the bottom of the wing and the brackets. The brackets were then riveted in.


 
Apr 10, 2024     Balanced Rebuilt Aileron - (1 hour) Category: Wings
We balanced the aileron with shot and epoxy and sealed the tube with expanding foam
 
Apr 10, 2024     Pitot Tube - (1 hour)       Category: Wings
We installed the pitot tube to the mount. We needed to trim the mounting screws shorter so there was no risk of puncturing the tubes. we also confirmed the fit to the wing.


 
Apr 08, 2024     Balancing the Right Aileron - (1 hour) Category: Wings
Sprayed foam into the rebuilt aileron so that shot and epoxy can be added.
 
Mar 04, 2024     Remanufactured Right aileron - (5 hours) Category: Wings
 
Feb 23, 2024     Finished balancing the left aileron - (1 hour) Category: Wings
Finished balancing the left aileron with shot, epoxy and foam
 
Feb 22, 2024     Balance left Aileron - (3 hours) Category: Wings
We poured a mixture of lead shot and epoxy into the left-wing spar. we then sealed off with expanding foam. We took extra care with this aileron after the right one fell yesterday and damaged it.
 
Sep 28, 2023     Wing to Fuselage Fairings - (2 hours)       Category: Wings
Cut and fit the fairings for the wing root.


 
Sep 21, 2023     Left Wing Strut Fairing - (1.95 hours)       Category: Wings
The faring was cut for easy removal and a fiberglass tab was added to support the the cut pieces. One side of the tab is not attached to the fairing. The mounting holes were then drilled through the fairing and the wing skin and then rivnuts were installed.


 
Sep 21, 2023     Wing Tips - (3 hours)       Category: Wings
The wing tips were covered with a material to hide the fiberglass and the cut-out indentation marks for landing lights. This was then sanded smooth and test fit to the wings.


 
Sep 20, 2023     Wing Tips - (4 hours)       Category: Wings
Sanded the fiberglass and then put body filler


 
Sep 20, 2023     Strut Fairing - (2.0 hours)       Category: Wings
The rivnuts were installed in the wing and on the fairing where the split is we put a fiberglass tab on the inside so that we can keep the 2 halves together.


 
Sep 19, 2023     Wing to Strut Fairing - (4 hours)       Category: Wings
We trimmed the plastic fairing. We then fit and cut the strut hole and then cut the fairing for ease of removal with out having to remove the strut.


 
Sep 19, 2023     Aerosport Wing Tips - (3 hours)       Category: Wings
Fitted up wing tips and noticed there was a slight height difference between the tips and the wings. Taylor and Chris layered fiberglass to even out the differences. They will sand tomorrow. They also installed all of the inspection port screw mounts.


 
Aug 24, 2023     New Wing tips - (8 hours)       Category: Wings
Taylor and brother Chris installed the rib and cut out the tip for the lights on the new Aerosport wing tips. The ones we built previously looked TERRIBLE.


 
Feb 18, 2022     Reattached the strut attach brackets - (.5 hour)       Category: Wings
Reattached the brackets to the wing trusses.


 
Feb 17, 2022     Strut Mounting brackets - (6 hours)       Category: Wings
I was extremely cautious (read took way too much time) in enlarging/match drilling the replacement brackets with the brackets that were fine. The brackets attach the struts to the wing trusses. We had elongated some of the holes when we first did the up-sizing drilling on 2 of the brackets on both wings.


 
Dec 17, 2021     Removed wings - (3 hours) Category: Wings
We took the wings back off. This makes it easier to store and move around and work.
 
Dec 14, 2021     Tighten all the bolts to the wing. - (1 hour) Category: Wings
 
Dec 13, 2021     Hung the wings - (2 hours)       Category: Wings
The right-wing went on fairly easy. The left not so much. I was happy we had extra bodies around to hold the wings while we figured everything out.


 
Dec 13, 2021     Struts - (4 hours)       Category: Wings
In preparation for attaching the wings, we still needed to up drill the hole to attach the strut to the wing truss brackets. We removed those and drilled them. This didn't go so well, we elongated the holes in 2 of them which will need to be replaced, I have ordered them, they are fine for this test fitting of the wings. We then discovered that we had reversed the lower attach knuckles and put them on the wrong ends of the struts. This came after much trial and error trying to first attach the strut to the fuselage and then trying to attach it to the wing.


 
Dec 10, 2021     Replaced incorrect rivet - (.5 hour) Category: Wings
As part of measuring the internal distance of the front spar at the bolt holes, we noticed that a rivet used at the front doubler was too long. We drilled it out and put the correct length one in.
 
Aug 02, 2021     Attached Wing Tips - (3 hours)       Category: Wings
It was difficult to get the bolts to thread...but finally were able to mount and tighten the bolts.


 
Jul 15, 2021     Wing tips - Project that won't end - Navigation light - (1 hour)       Category: Wings
The navigation/strobe light attachment was riveted to the wing tips.


 
Jul 15, 2021     Wing tips - Project that won't end - (8 hours)       Category: Wings
We repeated the process of match drilling the right wing tip and rib. Got almost all the way done.....we had forgotten the nut plate supports. We drilled out the rivets on both, luckily found the correct size rivets in the finishing kit (ordered replacements) and re-attached the nut plates to both wing tips with the supports.


 
Jul 15, 2021     Wing tips - Project that won't end - (5 hours)       Category: Wings
Left wingtip, we first tried match drilling the holes to attach to the wing......too difficult. After looking at the Rans video we marked the holes with a marker then after taking the tip off of the wing, drilled the holes. We then attached the nut plates.


 
Jul 13, 2021     Wing tips - Project that won't end - (2 hours) Category: Wings
Refined the Jig and the spacer for the wingtip glued the right rib and tip.
 
Jul 13, 2021     Wing tips - Project that won't end - (1 hour)       Category: Wings
Checked the re-glued left wing tip. It was MUCH better. I sanded off a lot of the excess adhesive.


 
Jul 12, 2021     Wing tips - Project that won't end - (.5 hour)       Category: Wings
Decided to attempt to re-glue the left wing-tip using the new jig and different glue. We will know tomorrow.


 
Jul 09, 2021     Wing tip - part from ...... - (7 hours)       Category: Wings
Looked at the glued left-wing tip. Rib had slid back and not very glued to the rib. We pulled it apart causing slight damage to the tip (very small crack). I sanded off the adhesive. Rather than work on that tip again I decided to work on the right. I spent the rest of the day making the jig for the right wing. I am taking EXTREME care on the fit of the jig.


 
Jul 08, 2021     Wing Struts - (6 hours)       Category: Wings
Son Chris and I worked on the Wing struts, after locating the parts. We match drilled and upsized the strut and the doublers. Deburred and then riveted the doublers on.


 
Jul 08, 2021     Wing tips - Project that won't end - (7 hours)       Category: Wings
Chris and Chris worked on the wing tip jig with a sander. Finally got it good enough to use. Some areas needed shims. Bro Chris when and picked up .05 aluminium to use as the shim between the tabletop and the rib and also bought ABS adhesive. Bro Chris worked on cutting out the aluminium shim. At the end of the day, we took the bold step and glued the rib and tip together weighing down the rib and the rip with sand bags......will know how it looks tomorrow.


 
Jul 08, 2021     Pro Sealed fuel cap right wing - (2 hours)       Category: Wings
The fuel cap was Pro Sealed to wing skin on the right-wing.


 
Jul 08, 2021     Rivet Left wing final rib - (1 hour)       Category: Wings
First thing this AM I finished riveting the rib that holds the fuel tank in on the left wing.


 
Jul 07, 2021     Installed fuel tanks in the right wing - (2 hours)       Category: Wings
Right-wing fuel tank was installed. We decided to junk the grommets provided by Rans for the fuel sight gauge and found ones that fit better, did this on both wings. Riveted the end rib in place after struggling to get the rib positioned between the skin and the support strut for the fuel tank. Pro Sealed around the fuel cap assembly.


 
Jul 07, 2021     Wing tips - Project that won't end - (6 hours)       Category: Wings
Finished trimming the tip to fit. Then started the jig to glue the tip to the plastic rib....took forever to get it to fit.


 
Jul 06, 2021     Fuel Tank - (6 hours)       Category: Wings
Pro sealed the screws of the fuel cap, pressure tested tanks then drilled the vent hole. We struggled with getting the wing rib back in after putting the tanks in the wing finally clecoed. Fuel sight gauges, decals, and grommets installed.


 
Jul 06, 2021     Continued working on the wing tips - (6 hours)       Category: Wings
Continued with the trimming and the fitting process.


 
Jun 11, 2021     Fuel Tanks - (4 hours)       Category: Wings
Installed the fuel tank internal support and attached the fuel cap and pro sealed. Pro Sealed all the tank fittings.


 
Jun 11, 2021     Wing tips - (8 hours)       Category: Wings
Last Day of our sprint so we decided to work on the wing tips. We taped and started the trimming process on the plastic tip and the plastic mounting rib.


 
Jun 10, 2021     Fuel Tanks - (5 hours)       Category: Wings
Worked on the left and right fuel tanks. Difficult to follow how tight wants the fittings to be on the tanks. Ended up buying an allen wrench on a socket to help tighten the smaller fittings. We finished the right tank fittings and started to work on the left tank. It was then noticed that on the right tank the rear hole was drilled at just over 3" from the measuring point VS 1 3/16". Checked with Rans and said this was OK.


 
Jun 10, 2021     Recreated Pitot tube Mount - (2 hours)       Category: Wings
After miss drilling the match holes to screw into the inspection port mounting ring. we measured precisely to a) make sure the mounting bracket would clear all the tabs of the inspection ring, B) would be facing perfectly forward. The hole for the pitot mount was created with a drill, grinder, and files. It was matched drilled and riveted to the plate.


 
Jun 09, 2021     Right Fuel Tank - (4 hours)       Category: Wings
Brenden made the tools for cutting out the required holes in the fuel tanks. He also worked on how best to do the fittings on the tank. What was tight enough but not too tight per the instructions.


 
Jun 09, 2021     Pitot Support - (2 hours)       Category: Wings
After carefully measuring where to position the pitot support to the port, I missed drilled one of the holes to the mounting bracket below ruining the base. So took the mount off the scrap base and started again. I had to cut the base two times. The first one was more oval than round. The second one was rough cut with a band saw and then refined with a sander. It was much better.


 
Jun 08, 2021     Finished Skins Right Wing Started Bottom Skin Left Wing - (8 hours)       Category: Wings
I was not at 100% so Chris did most of the work. Finished the right-wing bottom by match drilling and riveting rear spar and the inspection covers. We swapped out wings and checked for twist on the right wing. Then matched drilled front spar, dimpled, countersunk, deburred, and then riveted. Then riveted most of the rest of the skin. Chris ended damaging one of the corners of the fuel tank supports, talked to Rans and it was decided to replace and have it next day air for aesthetics vs redrilling inboard.


 
Jun 07, 2021     Attaching skin to bottom of the right wing - (12 hours)       Category: Wings
Positioned the bottom skin on the right wing. There was a slight interference between the skin and flap/aileron attaching bracket. It was filed to enlarge. After the skin and the inspection port brackets were clecoed the skin and the front spar were matched drilled, dimpled, countersunk, deburred and finally riveted. The rest of the rivets were installed leaving the last 4 near the rear spar only clecoed. This is done so that the skin and rear spar can be matched drilled. Note: I was not at 100% so Chris did most of the work.


 
Jun 04, 2021     Transferred right wing to jig and notched stringer for strut support - (1 hour)       Category: Wings
We flipped the right wing over on to the jig, clamped everything down, and then checked for twist. We were ecstatic that there was no shimming required. we partially clecoed the bottom skin on to locate the exact spot on the stringer were it needed to be notched for the strut support. Then notched it.


 
Jun 04, 2021     Assembled wing jig - (3 hours)       Category: Wings
While Chris and I worked on the gap seal on the right wing, Brenden assembled the wing jig. We bought 2 more 2x2 extruded aluminum pieces cut to length. We discovered that we attached the front one in the wrong direction - easily fixed, we didn't notice until we tried to put the wing on it. Notice in the pictures the front piece is in the wrong direction.


 
Jun 04, 2021     Gap seal installation - Right wing - (10 hours)       Category: Wings
Installed the right-wing gap seal. This time we made sure the aileron and flap gap seals were at a consistent separation between the piece that fits under the wing skin and the angled part that attaches to the rear spar. We used a hand seamer on both gap seals to make sure they were equidistant (squeezed it gently at the crease) This time it was a lot easier to make sure that they matched the angle of the wing skin. We matched drilled, disassembled, deburred, and then riveted the remaining wing skin rivets (all but the root rib) and the gap seal to the wing. We then checked the range of motion of the aileron and flap. 4 Rivets needed to be redone to on the flap, so it didn't rub. This went so much easier than the left. Were the two meet in the middle was almost perfect, not like the left.


 
Jun 03, 2021     Installed gap seal left wing - (11 hours)       Category: Wings
Installed the gap seal on the left wing. This included match drilling after trying to make it have the same angle as the wing skin. we had a heck of a time. We used the hand seamer to crimp it. I was a little overzealous on flap seal and dented the bottom a bit. where the 2 meet in the middle didn't line up like we wanted. When we disassembled to debur Brenden a dimple remover tool to get some of my dents out. After we reassembled we riveted the remaining wing skin rivets and the gap seal under the wing skin and also to the rear spar. We then checked for clearance. Brenden used a ball peen hammer, per the instructions, and creased the underside so the flap would clear. He was no happy on how hat looked, but the flap cleared.


 
Jun 02, 2021     Ailerons and flaps - (10 hours)       Category: Wings
Again, a very time-consuming day working on the flaps and ailerons. lots of remeasuring as we riveted, we were slowed by sharing the 1 smart level. EXTREMELY focused on not having any twist. We ended early at 2PM


 
Jun 01, 2021     Aileron and Flaps - (20 hours)       Category: Wings
Today was totally focused on the ailerons and flaps. We completed match drilling to the bottoms of ribs, after attaching the needed attachment brackets. On the left aileron match drilled and deburred to the spar. One of the most time-consuming things was to make sure there was no twist. Lots of measurements and shimming. Thankfully, we had the sandbags from before + I had brought another down. We transferred sand to gallon zip-lock bags so they were lighter.


 
May 07, 2021     Attached bellcranks to Right wing - (1 hour) Category: Wings
I was able to attach and safety wire both the aileron and flap bellcranks to the right-wing.
 
May 07, 2021     Work on left wing - (10 hours)       Category: Wings
Mainly focused on the left-wing. Bellcranks for aileron and flap were attached, including safety wire and lock tight. We ended up drilling holes in the rib flanges for the safety wires, after reviewing what others had done on the Rans S21 builder Facebook page. The plans were silent on where to attach the safety wire. The aileron cable and the flap cable were also attached. The electrical wire holes were drilled and grommeted on ribs 3-10 and the serrated grommets were attached on ribs 1 and 2 on both the left and right wing. After reviewing the Rans pitot tube attachment suggestion, it was decided to fabricated and riviet a plate through which the pitot and the AOA tube will be passed through grommets on the affected ribs. I asked Rans about how close the aileron cables are to rubbing on the strut attachment mount and whether this should be a condition inspection item. Here is the reply "Yes, add that to the list, we inspect that every annual, so far no issues, we do place anti-chafe tape in the area of possible contact."


 
May 06, 2021     Riveted Ribs to Spars - (8 hours)       Category: Wings
After we had clecoed the ribs to both spars, we bolted the strut support to rear spars. We then riveted the front and rear spars to the ribs, except rib 1. Completed both wings.


 
May 06, 2021     Riveted Hinge brackets and bell crank attachments to left and right wings - (8 hours)       Category: Wings
We riveted the hinge brackets and bell crack attachments to the ribs, after match drilling and deburring. We had drilled and deburred the be bell crank attachment holes.


 
May 05, 2021     Cut out wing shaping tool - (.5 hour)       Category: Wings
I had laid out the tools on a 1" cutting board at home using a protractor and a ruler. Cut it here as they have a band saw.


 
May 05, 2021     laid out ribs and numbered for both left and right - (.5 hour)       Category: Wings
Laid out the ribs in order and confirmed they were level. Had to swap some around as the end ribs are slightly different, I clecoed the angle mounts to the hinges and clecoed to the correct ribs.


 
May 05, 2021     Left wing strut mounting bracket issues - (.5 hour)       Category: Wings
After enlarging the bolt holes one was oblong and one of the mounting holes was too short. Emailed Rans and got this response - this is ok as long as the bolts pass through, and shimming to get an even footprint is a good idea.
We used a thin washer to shim. finished mounting the bracket.


 
May 05, 2021     Installed strut mount brackets to the strut support Rht wing - (.5 hour) Category: Wings
After enlarging the holes in the bracket and the support attached it to the support - not tightening the nuts.
 
May 05, 2021     Drilled and installed bushings in the aileron and flap hinges - (3 hours)       Category: Wings
used the drill press to enlarge bushing holes and then hammered in the bushings


 
May 04, 2021     Optional landing lights - (8 hours)       Category: Wings
Brenden spent the day measuring, cutting and drilling the brackets for the left and right-wing for the landing lights. He also cut the plastic for the lenses and test fit them.


 
May 03, 2021     Locating wing ribs and parts for tomorrow - (1 hour) Category: Wings
Emptied most of the crate to locate all of the ribs for the wings
 
May 03, 2021     Optional Landing openings - (4 hours)       Category: Wings
We spent about 45 min looking for the template first in the manuals, then in the crate. Finally found it and after marking the front spars the openings were cut with a grinder. The rest of the time was filing the openings so they were even.


 
May 03, 2021     Bell Crank - (2 hours)       Category: Wings
Completed the bell cranks. Added connecting parts to all four. I attached the safety wire to one of the aileron cranks after being shown by Brenden on the first one. I ended using about 5 feet of wire on the many multiple tries to get the one acceptable one.


 
May 03, 2021     Finished Riveting of doublers on Spars - (1 hour)       Category: Wings
After a long break for COVID, I started by finishing riveting the remaining doublers on the remaining wing spars. I also drilled out the required holes


 
Dec 29, 2020     Right wing spars - (1 hour) Category: Wings
I deburred the right-wing front spar (inside). I clecoed the doublers to the front and rear right spars.
 
Dec 29, 2020     Aileron and Flap bellcrank - (2 hours) Category: Wings
After buying a lock ring pliers brother Chris was able to finish both the left and right aileron and flap bellcrank assmblies
 
Dec 28, 2020     Began Work on Aileron and Flap Bell Crank - (1 hour)       Category: Wings
Located aileron and flap bell crank parts. Wedged the bearings into the aileron pulley and the flap bell crank.


 
Dec 28, 2020     Front and Back Spar. - (4 hours)       Category: Wings
Located all the parts for the left-wing spars. Then riveted the doublers to each. Did not rivet the holes that were supposed to not yet be riveted. Drilled out the bolt holes in the front spar and the doubler.


 
Oct 30, 2020     Shaped the flaps and ailerons - (4 hours)       Category: Wings
A 2" aluminum pipe was used to form the curve on the top portion of the skins for the flaps and ailerons. Holes were matched drilled to the holes in the skins. Skins were then clecoed to the pipe and rolled until the clecos rounded and touched the bottom of the skins. It took 3 of us to roll.


 
Oct 29, 2020     Cut the tabs off of the Flaps and ailerons. - (1 hour)       Category: Wings


 
Oct 29, 2020     Pulled and identified parts for the flaps - (1 hour) Category: Wings
Chris and Phil pulled all the parts for the flaps.
 


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