Project: TerryS     -     Entry

Oct 13, 2022 5 finished wingtip nutplates and W-412 wingtip ribs Category: Wings
Installed all the nutplates on the right wingtip, including installing the archer antenna.

Regarding the antenna: I looked at this pretty closely with respect to fore/aft location. It's kind of counter-intuitive. You would think that it would make sense to move this as far aft as possible to get it away from the nav/strobe wiring, but the instructions that come with it are very clear that the wire run to the lights should run up the forward leg of the antenna and be attached to the already-installed plastic clips. It also shows the coax running up from the rear along the leg that picks up the nutplates then making a U-turn to attach to the terminal screws on the aft leg of the triangle shape at a 90 degree angle to the that leg.

Both of these requirements lend themselves to a forward location on the RV7 wingtip and a search of VAF shows that seems to be what everybody does, so I located it forward as seen below.

There is no provision included with the antenna to keep the long leg from flopping around and possibly cutting into the fiberglass due to vibration, so I just taped the long leg down with some industrial duct tape. I plan to fly it this way for a while and if I don't need to relocate it for some reason, I'll likely replace the duct tape with a few blobs of adhesive, but I'm holding off on that for now because it's super thin and if it's firmly glued down I'm afraid I might wreck it getting it unstuck if that becomes necessary.

The W-412 wingtip ribs go in the back end of the wingtips parallel to the outboard end of the ailerons to close it out and stiffen it up. However, the plans don't give an exact location dimension. Because it's wedge shaped, it's easy to make that part of the wingtip spread out or suck down depending on how far aft you shove it.

Obviously, you want the cross section of the wing tip to match the aileron, so way back when, I had fixed its location when I first pilot drilled the wingtips to the wing. The fiberglass has a step about 2.5" forward of the trailing edge where there are extra plies to re-inforce the trailing edge. The aft end of the wedge was riding up on that step, so I had previously trimmed about 1/2" off the aft end of the rib to get it far enough aft that the shape was right. Basically, I just trimmed off enough that it butted up against the step in the fiberglass.

The print calls out 10 rivets in each flange of the rib on 1.5" spacing, and the length of the rib after trimming worked out perfectly for this spacing.

To make sure that it didn't shift and screw up the shape of the wingtip while I was drilling it, I devised a process that made sure it stayed where I wanted it; I drilled the two forward holes in the upper and lower flanges but on the aft end I only marked the rivet location so that i could still see it with the rib installed. I then attached the tip to the wing and attached the rib to the tip with cleco clamps. Once I determined that the location was good, I drilled through the wingtip into the rib at the aft location and clecoed the aft two flange holes.

I then removed the tips and match drilled the forward two holes with a 90 degree air drill. Once the holes on both end were clecoed, it was simple to lay out the rest of the rivet pattern with a rivet fan. I drilled all the holes, countersunk an installer rivets.

There's only 1/4" clearance between the edge of this piece and the outboard edge of the ailerons, so I was super meticulous with the placement and layout of these. Took a while but they came out operationally and cosmetically perfectly on both wingtips.

This concludes everything I can think of that I want to do with these wings in the garage, so Stacy Green is coming over after work tomorrow to help me move them to the hangar. I finished up the day by running to harbor freight for some more moving blankets in preparation for that milestone.


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