Entries for: Wings - General
| Entry Date: Tuesday, Oct 06, 2009 (details) |
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| Set the Dihedral Angle of the Wings, Mark & Drill Struts |
| Wings
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| General
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| 2 hours
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Check lateral-level of fuselage and set each wing at a 1.5 degree dihedral angle.
Checked wings for twist, adjusted as necessary.
Marked the struts for drilling.
Drilled outboard ends of the struts using the Glasair jig.
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| Entry Date: Monday, Oct 05, 2009 (details) |
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| Mount the Wings to the Fuselage |
| Wings
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| General
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| 5 hours
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(combining in one post - includes both sides)
Install the inboard wing strut fittings.
Mark the bolt centerlines on the strut attach arm and wing strut.
Triming of attach areas already completed in our quick build.
Mounted wing, inserted pins, fitted the struts for drilling.
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| Entry Date: Thursday, Oct 01, 2009 (details) |
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| Wing Riveting - Left |
| Wings
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| General
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| 50 hours
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(Trying to figure out complete hours.)
General Order Follows:
1) Main & cove ribs to the spars.
2) Leading Edges of the nose ribs.
3) Leading Edge assembly to the spar.
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| Entry Date: Friday, Jul 31, 2009 (details) |
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| Wing Components - Cleaning/Corrosion Protection Note |
| Wings
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| General
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| 1 hours
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During cleaning and corrosion treatment we implemented a new 'tagging' system.
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| Entry Date: Sunday, Feb 22, 2009 (details) |
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| Assemble & Mount the Flap Tracks |
| Wings
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| General
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| 1 hours
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Lay out and set out rivet pattern of the flap tracks. Cleco with the ribs.
Checked clearances and drilled.
Cleaned, deburred, painted and riveted the assembly together (repeated for both inboard and outboard).
Installed flap tracks on the spar.
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| Entry Date: Friday, Jan 30, 2009 (details) |
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| Assemble, Rivet and Mount the Flap Bellcrank Assembly and Bracket |
| Wings
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| General
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| 8 hours
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Assemble pieces, lay out rivet pattern per specifications and drill.
Clean, deburr, corrosion protect.
Rivet the assembly together and press the flap bellcrank bearing housing in.
Loctite and press the bearing in.
Assemble, punch, drill and prep the brackets.
Rivet the angles to the brackets, mount the bellcrank assembly, and rivet to the aft spar.
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| Entry Date: Friday, Jan 30, 2009 (details) |
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| Assemble the Aileron Hinge |
| Wings
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| General
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| 3 hours
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Assemble the aileron hinges based on manual diagrams.
Align, clamp, drill, deburr and clean.
Rivet pieces together and rivet to spar.
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| Entry Date: Wednesday, Jan 21, 2009 (details) |
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| Assemble the Aileron Bellcrank & Mount the Hinges |
| Wings
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| General
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| 3 hours
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Align the pieces of the bellcrank, clamp and drill. Assemble the brackets as well.
Deburr, clean, and corrosion-proof everything except the bearing.
Rivet brackets, assemble and fit to spar.
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| Entry Date: Saturday, Jan 03, 2009 (details) |
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| Fabricate & Mount the Outboard Pulley Brackets |
| Wings
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| General
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| 1 hours
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Fabricated the brackets, assembled the pieces and aligned on the spar.
Drilled, cleaned, deburred and painted.
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| Entry Date: Monday, Sep 01, 2008 (details) |
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| Finish Drilling the Skins |
| Wings
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| General
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| 15 hours
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Completed drilling on both sides.
Aligned and drilled the nose ribs.
Dimpled skins, countersinking on forward spar and flanges.
Deburr.
*Added 5 hours for cleaning, corrosion-proofing, and painting of all wing-bits. (estimated) Completed in stages through 8/1/09.
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| Entry Date: Saturday, Aug 16, 2008 (details) |
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| Position & Drill the Upper Skin Stringer Channels |
| Wings
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| General
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| 1 hours
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Since the channels were already in place the skins didn't have to be moved again for this step.
Re-positioned the channels with the lower skins off, supported and drilled.
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| Entry Date: Saturday, Aug 09, 2008 (details) |
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| Position & Drill the Upper Hat Stiffeners |
| Wings
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| General
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| 4 hours
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Remounted upper skins, removed lower. Repeated procedures to prepare the hat sections.
Position and drill.
Enlarge all rivet holes through spars and where the skin splices to #30.
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| Entry Date: Thursday, Jul 24, 2008 (details) |
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| Position & Drill the Lower Skin Stiffener Channels |
| Wings
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| General
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| 1 hours
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Fit the skin stringer channels underneath the lower skins.
Centered as well as possible and drilled.
(We changed the order from the manual and did this before the upper hat sections. Seemed to make sense not to waste time removing skins inbetween tasks)
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| Entry Date: Sunday, Jun 01, 2008 (details) |
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| Install Hat Sections Stiffeners & Lower Wing Stiffeners |
| Wings
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| General
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| 5 hours
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Checked each hat section for straightness. Corrected any issues.
Smoothed edges and rounded the ends on the grinder.
Marked rivet lines.
Position and drill.
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| Entry Date: Thursday, May 01, 2008 (details) |
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| Position & Drill the Lower Inboard Main Skin |
| Wings
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| General
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| 2 hours
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Same procedure as for all skins.
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| Entry Date: Friday, Jul 06, 2007 (details) |
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| Position and Drill the Lower Outboard and Center Main Skins |
| Wings
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| General
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| 0.75 hours
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Used the same method as attaching the upper skins and attached the lower outboard and lower center skins.
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| Entry Date: Sunday, Jul 01, 2007 (details) |
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| Finish Drilling the Upper Main Skins |
| Wings
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| General
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| 7.5 hours
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Attached all upper skins and rechecked the alignment.
Drilled all rivet holes: spars and ribs, forward spar flanges, main ribs, aft spar, and finally the flap and aileron cove ribs.
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| Entry Date: Thursday, Jun 14, 2007 (details) |
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| Mark and Trim the Leading Edge Skins |
| Wings
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| General
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| 3 hours
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With the upper skins in place and secured, marked anywhere the skins overlapped.
Removed the excess material with a file.
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| Entry Date: Saturday, Jan 13, 2007 (details) |
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| Position & Drill the Upper Main Skins |
| Wings
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| General
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| 2 hours
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Began with the upper outboard skin. Placed, aligned and drilled a few index holes.
Repeated this process with the other upper skins.
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| Entry Date: Saturday, Jan 13, 2007 (details) |
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| Finish Drilling the Leading Edge Skins |
| Wings
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| General
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| 4.5 hours
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Made sure the leading edge skins were properly placed and that the jig was straight.
Drilled all remaining spar holes (#40's) except for the lower spar flange for the inboard leading edge skin.
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| Entry Date: Tuesday, Jan 02, 2007 (details) |
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| Install the Forward Spar Caps |
| Wings
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| General
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| 2.5 hours
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Cut the aluminum for the caps, marked out the location and placed.
Deburred the ends and rounded the 'inner' edge of the caps.
Finalized placement and drilled a few index holes in the caps.
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| Entry Date: Wednesday, Dec 27, 2006 (details) |
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| Position, Clamp & Index Drill the Leading Edge Skins |
| Wings
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| General
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| 3 hours
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Placed each leading edge skin and clamped to check the general fit.
Removed the center and inboard skins, supported the nose ribs (glue/wood support technique), and realigned the outboard skin.
Clamped the skin and drilled a few index holes.
Repeated this process with the other skins.
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| Entry Date: Tuesday, Nov 14, 2006 (details) |
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| Drill Wing-Assembly Holes (ribs, spars, etc) |
| Wings
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| General
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| 7 hours
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*Note: We'll use one date, and maybe multiple big entries, 'cause this is being done over a loooong time.*
After attaching all ribs/etc to the spars, drilled up each hole to #30's.
Before drilling checked the alignment of each piece.
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| Entry Date: Saturday, Nov 04, 2006 (details) |
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| Mount the Strut Beam |
| Wings
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| General
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| 1.5 hours
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Installed the assembly between the spars and fastened.
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| Entry Date: Saturday, Oct 14, 2006 (details) |
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| Assemble the Strut Beam |
| Wings
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| General
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| 3.7 hours
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*We have the earlier kit which will have two holes at the aft angle, later kits will only have one.*
Cleco'd the strut beam halves and their attach angles together.
Pass drilled all holes common to the forward angles and reamed to 1/4".
Made sure to keep the holes aligned and the angles parallel to each other.
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| Entry Date: Thursday, Oct 12, 2006 (details) |
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| Reinforce the Root Main Rib |
| Wings
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| General
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| 2.5 hours
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*not complete yet*
Made the upper/lower root rib doublers, the reinforcement angles and the web doubler angles.
Placed all reinforcement according to the manual and drilled rivet holes.
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| Entry Date: Wednesday, Sep 27, 2006 (details) |
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| Fabricate Aft Spar Center Supports |
| Wings
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| General
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| 0.5 hours
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Built three supports for the aft spar.
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| Entry Date: Tuesday, Sep 26, 2006 (details) |
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| Mount the Ribs to the Spars |
| Wings
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| General
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| 1.5 hours
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(Marked rivets lines on the main ribs.)
Cleco'd the main ribs to the spars.
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| Entry Date: Sunday, Sep 17, 2006 (details) |
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| Fasten the Spars to the Jig Brackets |
| Wings
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| General
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| 2 hours
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Mounted the forward spar to the inboard bracket with a 1/2" bolt. Attached the outboard side with a cleco.
Double checked placement of outboard bracket and drilled/attached to the jig.
Once the forward spar was in place measured down from the brackets and placed the aft set.
Placed spar as before and checked level.
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| Entry Date: Tuesday, Sep 12, 2006 (details) |
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| Mark Rivet Lines on the Forward Spar Flanges |
| Wings
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| General
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| 0.5 hours
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Made a tool out of leftover 2x2 aluminum angle. Drilled holes in the angle to measure out the distance from the spar edge the lines needed to be.
Marked the lines relative to the spar edges.
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| Entry Date: Tuesday, Sep 12, 2006 (details) |
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| Install the Inboard Spar Brackets |
| Wings
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| General
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| 0.5 hours
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Used the jigs we made for the horizontal stabilizer build and attached one side of the brackets according to the manual specifications.
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| Entry Date: Sunday, Sep 10, 2006 (details) |
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| Fabricate the Wing Jig Spar Brackets |
| Wings
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| General
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| 2 hours
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Fabricated four brackets to 'attach' the spars to the jig.
Used 2"x2" aluminum angle and measured hole locations (for attaching and leveling) per manual instructions.
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| Entry Date: Thursday, Aug 24, 2006 (details) |
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| FYI: Please Excuse Our Building Boring-ness |
| Wings
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| General
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| 0 hours
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*EDIT* We've finished the left flap. Started setting up for *gasp* WINGS!!!*
Will still leave up the FYI that Shawn now has his Tail-Dragger Endorsment thanks to the J3 Cub at Northwest School of Aviation. WOOHOO!!! (aimee is also trying to figure out a new camera so pictures may be... odd... for awhile.)
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| Entry Date: Wednesday, Mar 23, 2005 (details) |
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| Wing Kit Arrival! |
| Wings
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| General
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| 0 hours
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Made a run to Glasair on the 16th and picked up our wing kit. We talked Shawn's dad into bringing his big trailer for the wing spars and figured we could fit everything on the trailer or in his truck. Too bad we could only put the spars on the trailer... the rest had to go inside.
Washington has had one of the driest winters on record and yet the day we scheduled for our wings is the day it rained. No wait, it poured!
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