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Sunday, September 30, 2012

Wing skins 8 hours

Today I worked on the remainder of the skins on the left wing. Also ran a 1/4" poly tube to the wingtip to serve as a conduit for wing lights and ran pitot and static lines

Saturday, September 29, 2012

Bottom skin drilling. 3 hours

Today I layed out the holes
In the bottom skins, drilled and clecoed them to the ribs. Then I disassembled, debuted and reassembled. Ready for riveting. Cut the 1"x1" angle for the rear spar and drilled it every 2". Clamped and started drilling and clecoing it onto the trailing edge

Friday, September 28, 2012

Trailing edge ribs 3 hours

Finished drilling and clecoing the leading edge skin. Then enlarged the 3/32 holes to 1/8". Removed the leading edge skin then attached the trailing edge ribs. Cut the bottom skins and bent the 1.75" bend at the trailing edge

Thursday, September 27, 2012

Attached leading edge ribs 4 hours

Today I attached the leading edge ribs. Also cut the left leading edge skin, bent, and layed out holes in the skin

Drilling leading edge. 3 hours

Tonight I layed the rest of the holes out in the leading edge skin and drilled them. Then I started at the top near the spar cap and started working the skin toward the leading edge and back to the spar. I got all but four rows on the bottom drilled and clecoed.

Wednesday, September 26, 2012

Trailing edge ribs. 8 hours

Yesterday I formed all of the trailing edge ribs. Also made the cutouts for the bell cranks and the indentations.

Monday, September 24, 2012

Cutting trailing edge ribs. 1 hour

Tonight I cut the trailing edge
Ribs, making sure to not get
Into the larger portion of the sheet that be used for the leading edge skin

Sunday, September 23, 2012

Attaching wing spars to center section. 8 hours

Today I set the dihedral and drilled
1/2" holes that attach the wing spars to the center section. Very tedious getting the dihedral set. Also reinstalled all of the rib attachment angles and tightened all of the bolts. Next session I will start laying out my trailing edge

Saturday, September 22, 2012

RIVETING. FINALLY. 58 hours total

Today I drove to a buddies house and finally riveted the spars and center section. He has a pneumatic squeezer set up in a jig that worked wonderful! Thanks so much. Well worth the 2 hr drive. Every rivet looks identical. Once I got home I took the upper wing attachment brackets off and drilled 1/4" holes for the 1/2" attachment bolts

4 hours( not including drive time)

Thursday, September 20, 2012

Clean up!

The shop was getting to be a mess, so I spent About an hour cleaning it up. I also put riveting tape on the rivets to make riveting go faster. Going to rivet Saturday morning

1 hour

Inserting rivets

Inserted rivets tonight getting ready for riveting

1 hour

Monday, September 17, 2012

Left spar deburring and priming

Today I disassembled the left spar, deburred, primed and reassembled it. Now I have the center section, left spar, and right spar ready for riveting. I will be riveting them this weekend at a friends house. Also worked on the compressor that was given to me. I needs a cylinder repair kit ( piston ring and cylinder), and new pressure switch . I ordered the wrong cylinder kit so it should be here Wednesday and will get it back together. Put the pressure switch on tonight and ready to finish wiring it.

3 hours

Sunday, September 16, 2012

Right wing Deburring and priming

I disassembled the right wing spar and debuted all of the holes today. Then I cleaned The parts and primed them. After that I reassembled the pieces. One more spar and I'll Be ready to rivet the spars

4 hours

Friday, September 14, 2012

Center section deburring and priming

I disassembled the center section tonight and deburred all of the holes. After that I primed all of the pieces
With self-etching primer. Decided to prime the spar being that it is an important part! Started reassembling the center section, but didn't get finished

3 hours

Thursday, September 13, 2012

Nose rib

Formed more ribs. Formed the right nose ribs

1 hour

Front rib forming

Worked on forming nose ribs(left).
Had to see what it looked like!

1 hour

Wednesday, September 12, 2012

Rib work.

I clamped all of my ribs that I cut out with snips together and hit them with the belt sander the get them all the same. Then I drilled the clamped stack for the jig holes and a 1/4 hole for the fly cutter. I used the fly cutter to see how it did and am happy with it. Took my forming blocks to the belt sander to put about a 10 degree bevel on the flange side of the blocks and re-fluted my indentions. Also took a little off of the blocks so my ribs matched the spar height. Formed another rib and like it

1 hour

Monday, September 10, 2012

Cutting front wing rib blanks

Tonight I traced my forming blocks onto a sheet of .020 aluminum, and cut them out. 18 total... Man my arm is sore! And I am a sheet metal worker by day! I cut them out with snips. I formed one up just to see how it would go and they are about 1/16" big after formed. So I am going to run the top and bottom edge along the belts sander again to take a little more off. I am also going to taper the flange part of the forming block about 10 degrees to allow the flanges to be over bent slightly to allow for the flange to "spring" back to 90 degrees. I assume I will have to file my indentions in the forming blocks a little deeper to maintain the "flute" that I have now. I'm pretty happy with the first rib. It lays flat on the table. Next work session I think I will work on putting the jig holes and the lighting holes
In the blanks.

1 hour

Sunday, September 9, 2012

Relief indentions on forming block

Today I bought a 1/8" radius bit for a router and put a radius on the edges of the forming block edges that the metal will be bent over. Worked like a dream! Also took my rat tail file and filed
The indentions on the forming blocks. Ready to make a rib! Got my little helper with me today

1 hour

Working on forming blocks

I bought a Sheet of 7 ply birch plywood to make my forming blocks
From. I made a copy of the section of the plans that have the rib templates on it and glued it to the sheet of plywood. Some advised against gluing it to the wood because it would cause the template to grow. I checked it and it is not and issue. I cut it out to approximate size and cut another piece of plywood the same size. Then I screwed the two together and cut to the bend line on the band saw(cut the flanges off, I'll add them to the metal later). Took them to a buddies to use his belt sander to clean them up(I'll definitely need one of those).

1 hour

Finishing 4130 steel brackets

I finished the 4130 steel brackets and got them attached to the left spar and top of the center section. I Left the bottom attachment brackets loose from the center section following the plans recommendation.

2 hours

Monday, September 3, 2012

Left spar assembly

Got another good day of work in today. I assembled the left spar, drilled and clecoed it. I cut and attached the rib attachment angles as well. I cut two more of the 4130 attachment brackets, now I am waiting on the rest of my order of the 4130 steel to arrive. Had to make more room in my shop, so I had to get rid of a couch I had for watching football. I got an air compressor given to me today but I have order some parts for it. Hopefully I'll get it going in the next week. Once
I get the rest of the steel cut and attached, I will take it all apart and deburr prior to riveting. I am still debating on whether or not to prime the parts. I've been told both ways

6 hours

32 hours total