Finished Flap Brace, Inspection Ports

November 13, 2012

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Well, with a few short minutes available to me in the garage tonight, I tied up a couple loose-end rivets and started on a new little mini project.

First, I pulled off the right flap and set these nine rivets with my economy squeezer. No big deal.

Hooray, now the flap brace and flap hinge is completely riveted.

Another angle, showing a completely cleco-free inboard wing.

Then, with about 15 minutes left, I pulled out the inspection covers.

I forget the part number, but there are six of them. Three for each wing.

Up to the drawing to see what hardware is needed.

Looks like #8 hardware.

Go searching through my hardware containers…

There they are.

Uh oh. There’s another set of hardware there on the left for the forward side of the inspection covers.

Oh no!

Oh yes.

I drilled the first forward edge to #19 drill size, then dimpled for a #8 screw.

After trying to fit a #8 screw into a #6 nutplate, I realized my mistake, and drilled them correctly on the other 2 (I’m only working 3 at a time.)

Foreground is correct (#6 screws), background is WRONG (#8 screws).

It’s a sad day when I have to make a deposit into the scrap bin. (sigh)

But, I kept at it, and borrowed one of the left wing’s covers (they aren’t handed, just one of the ones that were allocated for the left wing.)

I got them screwed into the forward (bottom in this picture) edge, and started matchdrilling the center holes.

They’ll look good when they’re done.

0.5 hour, 9 rivets.

Time to go run!

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Some More Right Wing Lower Skin Riveting

November 4, 2012

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Well, I decided that with an hour to kill this afternoon after the Bears game (they whooped up on the Titans), I would go outside and see if I could do something productive.

I managed to get a few more rivets set in the bottom skins.

Let me apologize in advance, the pictures are in a weird order.

First up, I peeled back the skin to make sure I could get to the rivets I was interested in. But also, AND THIS IS KEY, you have to make sure that once you set those rivets, you won’t back yourself into a corner where you can’t reach another set of rivets, so I checked (what I’ll call) “future” rivets.

Basically, I reach through the lightening holes and then up with the bucking bar.

I can reach both sides for about 4 rivets before I have to reposition a little.

Also, be sure to be carfeul with the skin. Even the manual warns about creasing it.

After spending so much time cleaning, I was amazed at how quickly the workbench started filling up again.

I’m going to make an effort to keep everything clean at the end of each work session.

After 30 minutes of (loud) shooting and bucking, I called it quits on the loud stuff for the day.

I did the last wingwalk rib, and the main and aft spar rivets just outboard of that rib. I colored the heads black where I set them, just to help me count. This was 40 rivets.

Since the skin doesn’t have to be peeled back as much anymore, I set another 13 rivets of the hinge. (I’m getting good at installing and removing the flap. Not that I have to, I just like to store it on the wing. Seems the safest there.)

I also pre-loaded the next bay of rivets.

If you’re counting ribs, I am now halfway (4 of 8) done with the lower inboard skin. It’s going to get easier moving outboard, too.

I like seeing the clecos slowly disappear.

1.0 hour. 53 rivets. It’s not really a streak until it’s three days in a row, so don’t jinx me.

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Started Riveting Right Flap Hinge to Wing

November 3, 2012

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Whoa. He’s back. Again. I know the updates have been few and far between, but please rest assured: I have not been working on the airplane without updating the site. I guess that’s not a good thing either…

I spent a few hours today cleaning out the garage and reorganizing a little.

Much better. (Sorry, you don’t get a “before” shot.)

Then, I decided to work on the airplane. Since I haven’t coordinate the cousin to come over and bang out some of these bottom skin rivets, I figured I could rivet the flap hinge up until it prevents me from bending back the skin.

It should be just a couple rivets.

I do need to trim the one side of the flap hinge, though.

You can just barely see that I made a mark on the hinge.

After removing the flap.

Here’s the trim line on the outboard side of the hinge.

This is pretty self-explanatory.

This one, too.

Oh yeah, I needed to smooth out the eyelet remnants where I had snipped them off to make a centrally-inserted set of hinge pins. See this post for more.

All smooth.

Looks pretty good on the outboard side.

Same on the inboard side.

Let’s get to riveting. The rivet callout here is an AN426AD3-4.

I love these yellow bins. Highly recommended for your project.

I didn’t really feel like getting out the rivet gun (and I can’t use my no-hole yoke because the eyelets get in the way), so I made it work with my economy squeezer.

An action shot!

After 8 perfect rivets, I couldn’t help but take a picture of some shop heads.

Look at how perfect that guy is!

0.5 hour. 8 rivets. Again. Not bad for not working on it in 2 months.

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Started Preparing the Right Wing Lower Skins

August 5, 2012

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Well, after a busy morning at the SCBC, I did get an hour in on the lower right inboard skin. I’ve decided to go ahead and close up the right wing before proceeding. A lot of people wait until much later in the project (which the instructions say you CAN do if you want), but everyone who waits says there is no real benefit to waiting, so I’m going to go ahead and get them closed up now.

First, I pulled the skin off the wing, and then got to work. I spent about 30 minutes edge finishing, then another 30 dimpling about half the skin with the c-frame. (No, I didn’t forget to drill or deburr, I had done those previously.

This picture is from after edge finishing, but before dimpling.

After I finish dimpling, I’ll prime the inside surface. Then, I’ll deburr and dimple the wing ribs, and rear spar, but I’ll need to remember to countersink the flap brace.

1.0 hour.

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Finished Right Flap!

July 30, 2012

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Well, after approximately 6 months of completely neglecting the airplane, I finally completed another big assembly on the airplane. Here are the gory details.

Yesterday, Taylor and I got all the rib-to-skin rivets set, so today, we finished up the spar rivets and cleaned up a few badly set rivets. Here we are with the every-other method on the lower flap skin (spar) rivets.

Look! no clecos!

Then, we finished getting the two exterior ribs in place. I did make a stupid mistake here, though. The spar rivets are all AN426AD3-4 rivets, and I just continued with that size around the side to the ribs.

Those ribs are SUPPOSED to be AN426AD3-3.5 rivets, so when I went to squeeze the -4s, they all bent over and sheared.

Nastiness here.

Ahh!

After some mild curse words,  some deep breathing, and FIVE drilled out rivets, we realized our mistake and got the correctly-sized rivets in there.

Shiny bottom!

I had Taylor shine up the skins. (By “shine” I really mean “remove all of Andrew’s fingerprints.”)

Shiny bottom skin!

Shiny top skin.

I forgot how much fun it is to finish a big assembly.

It’s a wing!

1.0 hour, counted as 1.5 man-hours. 78 rivets, 5 drilled out.

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More Right Flap Work

July 25, 2012

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Alright, another night in the workshop. And, tonight was a super-night. Not because I’m super-rv7-builder (I am), but because my cousin Taylor came over to learn about the airplane.

After a little talking, I put him to work.

First task, empty out the LP4-3s that just arrived from Van’s (my first airplane package in awhile) into one of my empty yellow bins.

Not off to a great start, Taylor.

He quickly started exceeding my expectations though. To get going on this flap, the next few steps are tedious, but the two of us working helped to lessen the pain.

We focused our attention on prepping the right flap lower skin deburring, dimpling, priming, etc.

Here’s the right flap lower skin. Not a really helpful picture. Oh well.

After showing him each of those “d” activities, We stuck the skin outside and proceeded with my new non-psycho masking prime job.

(If you remember from a few posts (months) back, I’m only going to do the straight-line vinyl trick with areas where someone can see. Parts that are closed off will get this treatment.)

Priming along the rivet lines.

Next up, the same trick on the interior ribs.

Deburr, dimple, scuff, clean, and prime.

It started to get dark out, and I needed the flash. Sorry.

Then, so we could end on a high note, we studied the plans a little, read the instructions (a novelty!) and started clecoing everything together to get a sense of how we should assemble this flap.

Here, the ribs and spar are clecoed to the lower skin to lock everything together.

It’s starting to look like an airplane!

Flipped over for some more clecoing.

We decided we could start by grabbing the four AN470AD4-4 rivets at the aft end of each interior rib.

Beautiful! (Stefan, look! another shop head!)

One of Taylor’s (damn, looks better than mine!)

Just to prove he was there, I took a picture of his toes. (And an airplane part.)

Since he was so productive and really saved me some time, I’m going to count his hours as straight hours.

2.0 hours (but logged as 4.0). 4 rivets.

I know 4 hours per week won’t be super speedy, but it’s a hell of a lot better than I did between January and July of this year.

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Right Flap Hinge Retention

January 22, 2012

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Alright, with all the excitement of getting the flap on the wing, I decided that I might as well continue with the flap hinge.

Currently, the flap hinge pin hangs out 2 feet on the inboard side of the wing, so let’s get that thing cut down to a reasonable size.

I’m following the method of cutting some hinge eyelets from the middle of the wing/flap and attaching two halves of the hinge pin in the middle. At the end of the last session, I had marked the middle eyelets.

Here's me unbending the two middle eyelst on the wing so I can cut them off.

Where's my file?

Can’t find it. I’ll have to clean those up later.

I cut the hinge pin in half and 90° bent them.

OMG, more toes!

With some careful measuring, cutting, and bending, I got one of the halves right where I wanted it.

Like a glove.

Then matched the other side to that.

Like some other builder’s, I’m going to use the hinge eyelet method of securing the hinge pins.

During this whole process, I kept thinking how easy it would be to drill a single hole in the flap brace and just safety-wire these two hinge pins in, but I couldn’t bring myself to not finish with the original plan. More later.

Two of my hinge eyelets from scrap.

The hardware I’m going to use.

I'm using the 2-lug, MS2169106 (I think that's right) and the AN507-6R6 screws.

There's a nutplate under there.

Rivets set.

The two eyelets are not countersunk or dimpled. I'll eventually need to replace this countersunk head screw with a panhead.

After getting the hinge pins secure, I checked out the outside.

Yikes. I'll definitely need to clean those up.

2.0 hours. Really? That was 2 hours? I couldn’t believe it. Maybe I fell asleep or something. I have a visitor coming this weekend, so maybe I’ll try to prep some flap parts before then so we can bang some rivets while he’s here.

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