Nov 02, 2022     Section 20 - Bottom Wing Skins 10 - (5.3 hours)       Category: Sec 20 BWS

The final session for wing closure started with riveting the bottom skin outboard. The challenge on this one was to plan the riveting sequence to ensure that the pitot mast would be in place before I lost reach to the deeper rivet locations. With the stiffener attached and the skin closed, I went ahead and installed the pitot tube. I used 4 AN507-6R6 screws cut shorter. The installation looks clean and secure. Inside the wing, I connected the hoses and wire bundle for the pitot heat controller. )see pic 173.12-173.19)

After the pitot tube, I installed the magnetometer and flaps. I put a sign on the wing to avoid magnetic fields on the root end of the wing, closer to where the magnetometer is located.

Finally, inspection plates are put in place, general clean up, and prepared to reengage the aileron construction. The new aileron skins arrived yesterday and will be the next project. Section 20 concluded.

https://youtu.be/UrKJdYjT00k

  Nov 01, 2022     Section 20 - Bottom Wing Skins 9 - (6.2 hours)       Category: Sec 20 BWS

In this work session, I am attaching the wing bottom skins to the skin. Once finished with the right-wing I attached flaps and secured the control surfaces and inspection ports.

Moving forward, I started with the left wing. before starting to attach the skin, I made some adele clamps installation to secure the magnetometer wire bundle. (See pics 172.26 and 172.27) After securing the wires, I installed the inboard bottom skin and short J stiffener.

https://youtu.be/Q4vG-hGtkc0

  Oct 29, 2022     Section 20 - Bottom Wing Skins 8 - (4 hours)       Category: Sec 20 BWS

In this work session, I continue to close the bottom skin. This time the right-wing outboard skin.

https://youtu.be/cwF41zP-JT0

  Oct 28, 2022     Section 20 - Bottom Wing Skins 7 - (3.2 hours)       Category: Sec 20 BWS

Back to the bottom wing skin session, I attached the first inboard skin. I understand now why Van's has the guts of the wings installed in a further step. Although it looks reasonable to install all internal components to only then close the wing, doing this limits arm and hand access to the back of the skin with the bucking bar.

https://youtu.be/3-S7tqdkemo

  Aug 30, 2022     Section 20 - Bottom Wing Skins 6 - (2 hours)       Category: Sec 20 BWS

Installed coax cables for NAV antennas and laced all wiring to make it neat and clean. I found that the molex connector for the wing tip lights was not well crimped on the green wire (awg 22 or 24). I had to redo this connector.

https://youtu.be/qDufEf7aoC8

  Aug 28, 2022     Section 20 - Bottom Wing Skins 5 - (8.3 hours)       Category: Sec 20 BWS

In this work session I am finishing up the pitot mast installation on the bottom wing skin, installing the pitot heat controller unit and wiring, routing the pitot and AOA air hoses through ribs, and installing landing lights.

I decided to install the pitot heat controller on the main spar web using 4 LP4-4 rivets. It is very easily accessible via inspection panel and secure. the wiring is a 14AWG black and red for power and one 20 awg blue for signal. I clamped the power wires in the vise and, using the electric drill on the other end, I twisted the wire pair. Not required but I decided to do that as an extra effort to avoid interference on the magnetometer and other components. When passing through the magnetometer bay, I re-routed the wire to stay as far as possible from the magnetometer. I will do the same with NAV antenna wire.

I used a wire clamp to accommodate, organize and secure the pitot tube wires and tubes (pic 144.42). This setup is perfect but the clamp is too wide. I ordered some smaller ones to replace this larger one.

Currently, I have some zip ties holding wires in place but intend to use wire lacing.

https://youtu.be/goOVjquAeCI

  Aug 25, 2022     Section 20 - Bottom Wing Skins 3 - (4.5 hours)       Category: Sec 20 BWS

Priming of Bottom Wing Skins parts.

550ml of primer used

https://youtu.be/QihiDX3xus4

  Aug 23, 2022     Section 20 - Bottom Wing Skins 2 - (9 hours)       Category: Sec 20 BWS

This work session was to prepare the bottom skins and associated parts for priming. None of the skins will be installed at this point but I will have everything ready before moving on to the next sections.

The job today involved smoothing and deburring all parts, dimpling skins, masking all parts for priming, and cutting the skins for the pitot tube probe mast.

The skins are overlapping in the middle of the wing and one of the corners where they overlap needs to be sanded down for a smoother, thinner overlap joint.

Pitot tube mast installation went super smooth but I was concerned that I could ruin the big skin part. Hopefully, it didn't happen and it turned out great. The first step I took was to cleco the provided template into place on the outside of the skin. after being happy with the position, I taped the template to the skin so it wouldn't move and started drilling out the opening for the mast.

Carefully I sanded the hole to perfectly match the mast shape and placed the mast in place. Did the first hole holding mast with my hand and from there, clecoing and drilling all holes. Lastly, I drilled the hole on the rib that will support the angle that supports the base of the mast.

With the mast temporarily attached, it was time to test fit the pitot tube and drill the screw holes. I had to cut the pitot and AOA tubes shorter to fit in the wing. Moving forward I did the flare on the tubes and installed the AN fittings with 20 in-lbs torque and the quick tube connection with NPT connection and 567 sealant. For this one, I was able to make 1-1/2 to 2 full turns. I blew air through pipes while closing pitot and AOA holes and looks like the seal is good. no leaks.

To level up one notch, I did a countersink on the mast base so that the rivets on the wing skill would be flush.

To finish the session, I prepared the inspection plates and the support for the magnetometer. Now all parts are ready for a big priming session.

https://youtu.be/UUlJ6ldw61Y

  Aug 22, 2022     Section 20 - Bottom Wing Skins 1 - (6.1 hours)       Category: Sec 20 BWS

In this work session I started preparing the parts for the bottom wing skins. I will have all parts ready, dimpled, and de-burred, but I will not actually close the wing. I dimpled all J-stiffeners, prepared the cradle for the magnetometer, and drilled nut plate holes in the inboard rib.

https://youtu.be/HLtylwT-ap0