The Case of the Missing Scarf

November 12, 2012

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Today, I had a day off work. This was excellent news because:

1) I needed a day off work.

2) The airplane needed me to have a day off work to get some stuff done.

Really, there are only a few things left on the right wing before I can call it complete and catch the left wing up. The lower outboard skin, inspection covers, pushrods, and wingtip. I’ll probably wait until both wings are complete to do the pushrods and wingtips.

That leaves the skin and the inspection covers.

Here’s the lower outboard skin, just kind of hanging on the wing (makes for good storage).

Also, You can see I kept my extra pieces of blue tape here while I finished the inboard skin.

After pulling the skin off, I realized that I already prepped the skin through deburring and scuffing the inboard side. Nice!

Already scuffed. (If you look at the date of the linked post, it was February….of 2011. Ouch.)

I guess you also get a closeup.

Anyway, I got the C-Frame out again and dimpled all the holes.

I did not dimple the wingtip attach holes. Haven’t even thought about those yet.

After dimpling, I cleaned the skin, took it outside, and got it primed between rain showers.

Back in on the workbench, it’s drying.

I still like doing the blue vinyl stripe trick.

While the skin dries, I went ahead and deburred and dimpled the rear spar. I was so lazy when I did the inboard wing, I only deburred and dimpled the holes required to get that skin in place.

Dimpling…done.

Then, I did the same deburr/dimple trick on the remaining spars.

You can see my conduit and wire-pulling string, also.

I guess this is another angle.

Okay, primer is dry. Let’s pull off the blue vinyl before getting the skin in place.

One bay.

All the bays. Man, those clean lines look good.

Oh, almost forgot to mention. Anytime you have a lap joint with two skins, don’t forget to use the edge roller to put a little kink in the edge. It helps lay the edge down when the two skins are pulled together.

My edge roller.

Here’s a good shot of how the skins lay on top of each other after rolling a bit of the edge.

Nice seam there.

After that, I didn’t think there was anything else before getting started. (I’ll come back to this.)

Getting the skin clecoed on.

After getting the first bay riveted, I realized I had forgotten to bevel the two skin edges like I had on the upper skins.

So, here’s my plan: leave it alone. The  amount it sticks up is minimal, and the bottom of the wing is less critical than the top (so says physics). I’ll either remember on the left wing, or do it the same so they are symmetrical. I’m going to go talk to our super-smart aero guys to see if there is any real concern.

After the first bay…

Then, with much straining, pulling, pushing, stretching, etc. I managed to get the second bay done, too.

To help you see what I’ve completed, I pulled the blue vinyl off where I’d finished.

It looks soo good.

Counting rivets, that two at the top is a “carry-the-two.”

So. 3.5 hours, 107 rivets. Not bad.

Taylor, get your butt over here so we can do some more.

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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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Finished Right Lower Skin Wingwalk Ribs

August 28, 2012

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Not much excitement today, just a few more rivets on the lower inboard right wing skin.

I was riveting solo today, so not many pictures either.

Here’s one of a couple shop heads. Not sure why I even took this picture. Maybe to show you that I was using some black felt to protect from dropping the bucking bar.

Boring picture, anyone?

After reaching in, under, and around the wingwalk ribs, I got all the rivets set.

And, I’m prepped for some duel riveting. Maybe tomorrow?

0.5 hour. 32 rivets. Not bad.

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More Right Lower Inboard Skin Riveting

August 15, 2012

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Today, while waiting for the DirecTV guy to show up (insert long story here about how I took the whole afternoon off to cover his time (12-4pm) and then he didn’t show up until 5:30pm), I ended up taking some time out for the airplane.

Taylor and I riveted six rivets on the inboard edge the last time he was over. It turns out, I really needed to bend the forward edge of the skin “up” in the picture to reach the aft row of rivets.

So, I drilled out three of the rivets, and was able to reach in from just below the main spar (bottom of these pictures) to buck the top row of rivets.

After setting the top (aft? oh man, we’re going to have trouble communicating with our different frames of reference) row of rivets, I worked down one rivet at a time for the two middle wing-walk ribs. (The inboard or left rib can be squeezed at the end, and the outboard wing-walk rib can be bucked by reaching from outboard after the wingwalk ribs are done.

Here’s the top row riveted.

To help me know where I was, I colored each rivet black with a magic marker after setting it.

After an hour, I made it about halfway down the rib.

From here on, I won’t be able to peel the skin back from the bottom anymore, but I should be able to reach in through the inboard rib, where the lightening holes are now big enough for my huge biceps.

1.0 hour, 33 rivets. 3 (originally perfect) rivets drilled out due to lack of planning. Boo.

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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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Right Flap Brace and Aileron Gap Fairing

December 12, 2011

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Alright, before we get too busy getting excited about two posts in a row, let’s talk a little about Christmas. This year, we decided to do a Christmas tree. A few Saturday’s ago, we ventured out into the cold (it was pretty warm) and cut down our own tree (no we didn’t, we bought it from the farmer’s market).

Anyway. There are three interesting pictures from the day.

Jack, incredulously watching us decorate the tree.

Ginger's falling asleep. OMG this is the closest she's been to feather's since FEATHERGATE.

Finally the tree.

Now it needs some presents. Send me some presents.

Just kidding.

Let’s get back to building, shall we?

Tonight, high on the excitement of flipping the right wing over, I decided to get some more aluminum down from storage.

These two pieces are the Aileron Gap Fairing and the Flap Brace.

Part numbers shown for the right wing.

Turns out these have been in the garage for over a year now, so when I pulled off the blue vinyl, there was some residual…well…residue.

A little acetone fixed this right up.

I scuffed these up quickly (I’ll do this more completely when I’m about to prime) and got out the right aileron brackets. The top of the inboard bracket was interfering on my wing (like everyone else’s before me), so like them, I ground down the top corner a little with the scotchbrite wheel.

Here's the corner I ground down.

And clecoed in place.

The outboard bracket clecoed in place.

Here’s the flap brace, looking inboard.

I'll matchdrill both sides, but only rivet the brace to the spar now, the skins will come later.

The flange on the inboard most section is sitting a little funny, so tomorrow, before matchdrilling, I’ll see if I can’t straighten this out a little.

Crooked flange.

Flap brace looking from inboard to outboard.

Then, I clecoed on the aileron gap fairing.

With no trimming, look at how nicely everything lines up. Man, this is easy.

30 short minutes tonight, but it’s better than nothing.

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