Once the wing is hung on the jig construction progress pretty quickly. There are only seven skins to work with, including the two top and two bottom skins, the outboard leading edge and fuel tank skins, plus an extra doubler skin under the inboard top skin to reinforce the walking surface of the wing.
Building the fuel tanks does take a fair amount of time and is a messy job. The aluminum skin, a rear baffle plate, and the two end ribs form the fuel tank. To keep fuel from leaking out along all the joints, a fuel tank sealant is applied to all the joints just prior to riveting. This sealant, called Proseal, quickly gets on everything and is a mess. Adding to the fun, there are fuel line fittings, fuel pickup tubes and fuel sender floats to install. In the end, my tank passed the leak test.
I added a Gretz pitot tube mount bracket on the left wing for later installation of their heated pitot tube. I'm holding off on riveting the bottom skins until late in the project. This will allow easier installation of the autopilot servo, wiring and pitot tubing. I'm also waiting to work on the wingtips so I can do all the fiberglass parts at once.
Total Construction Time: 172 hours
July 17, 2006 (2 hours)
Riveted the left main ribs to the main spar.
July 18, 2006 (2 hours)
Riveted the left main ribs to the rear spar.
July 24-25, 2006
Family vacation at Oshkosh!!! Having never been there, it was amazing to see so many planes in one place.
July 29, 2006 (6 hours)
Built wing stand support brackets, hung the left wing and aligned it so there's no twist from end to end.
July 30, 2006 (6 hours)
Made a support block for under the center of the spars. Then cleco'ed and match drilled the wing skins and wing walk doubler to the spars and ribs. Also cut the J-stiffeners to length and positioned along the ribs.
July 31, 2006 (1 hour)
Drilled the holes in the J-stiffeners. Also partially hung the bottom skins, but only with a handful of clecos.
August 1, 2006 (1 hour)
Cleco'ed the bottom skins.
August 2, 2006 (1 hour)
Match drilled the bottom skins and then made the leading edge / tank cradles.
August 3, 2006 (2 hours)
Trimmed the rear flange of one of the nose ribs to avoid the spar rivets. Straightened the flanges of the nose ribs to 90 degrees, then cleco'ed the top side of the nose skin to the ribs.
August 5, 2006 (10 hours)
Got the bottom side of the nose skins cleco'ed to the ribs, then mounted the assembly on the spar. Had to notch out the end support angle for the end of the skins. Then match drilled all the nose ribs to skin and spar holes. Next straightened the flanges of the tank ribs and attached it to the top side of the tank skins. Running short on clecos so ordered more along with some Proseal for the tanks. Then I fabricated and deburred the stiffener angles for inside the tanks.
August 10, 2006 (1 hour)
Worked hard to get the top skin cleco'ed to the two end tank ribs. Rest are proving to be a challenge.
August 11, 2006 (1 hour)
Cleco'ed the bottom side of the skins to the tank ribs, then also cleco'ed and match drilled the stiffeners. When I placed it on top of the spar, it seems there's a small misalignment of the tank skin to the outboard leading edge skin. Have to think about that for a bit.
August 12, 2006 (6 hours)
Started prepping the tank attach brackets using Van's method, but decided I didn't like that approach. Decided to start over using Dan Checkoway's method, which looks like it will work much better. I'll need to reorder a few of the brackets before I get going on the right side. Very slow progress either way. Got as far as drilling the holes for the bolts and the nutplates on the aft flanges.
August 13, 2006 (3 hours)
Countersunk the holes for the nutplates and deburred the edges of the brackets. Alodined the brackets then riveted on the nutplates.
August 16, 2006 (2 hours)
Took the ribs off the skin and did some re-bending of the leading edge to try and get a little better fit. Got it partially put back together and cleco'ed, but it's not much easier than the first time around.
August 17, 2006 (2 hours)
Got the tank skin cleco'ed to the ribs. Found the best way is to cleco the first four on top, then the first four on the bottom, but making sure the jig is far away from the rib you're doing. Then it was quite easy. Also riveted the three nutplates to the spar at the most inboard rib. Still have a slight mismatch of the tank leading edge where it meets up to the outboard leading edge skin, but think it'll work out okay.
August 19, 2006 (6 hours)
Reworked things to get a nice tight fit between the tank and outboard leading edge skins. Then I was able to position the tank assembly, remove the outboard and tank skins to finish drilling the holes in the tank brackets through the baffle holes. Also worked to get the two skins to match up better so one didn't stick out further than the other where they butt. Match drilled all the tank holes and drilled out the splice plate and tank screw holes. Finally I re-measured for any twist in the wing and I can't measure any.
August 20, 2006 (5 hours)
Countersunk the tank skins along the baffle rivet line. Then made the T-905 Tank Attach Brackets and the T-410 Nose Reinforcing Plates and drilled the needed holes.
August 21, 2006 (1 hour)
Used my unibit to drill holes around the perimeter of the access hole in the inboard rib.
August 23, 2006 (1 hour)
Finished filing and deburring the access hole in the inboard rib.
August 25, 2006 (1 hour)
Deburred the access plate and reinforcement ring. Then drilled the holes for the screws and platenuts, dimpled the platenut rivet holes in the rib and countersunk the matching holes in the reinforcing ring.
August 26, 2006 (1 hour)
Riveted the platenuts to the reinforcing ring and ribs.
August 27, 2006 (2 hours)
Drilled the fuel cap flange and fuel drain to the skins and countersunk the fuel cap flange. All parts are ready for final deburring and dimpling. Finished deburred all the holes in the baffle.
August 30, 2006 (2 hours)
Deburred and dimpled the tank rib and stiffener rivet holes, then roughened the faying surfaces with a scotchbrite pad.
September 2, 2006 (8 hours)
Roughened up the tank skins along the rivet lines. Then deburred and dimpled the rivet holes. Primed the T-905 tank support bracket. Finally I used acetone and MEK to clean all the tank parts. Ready to start riveting tomorrow.
September 3, 2006 (4 hours)
Prosealed and riveted the stiffeners, fuel cap flange and drain to the skins. Note the missing vent tube clip at the filler cap flange. I later drilled it out and added it.
September 4, 2006 (6 hours)
Prosealed and riveted a small piece of aluminum over the tooling hole in the outboard end rib. Then I taped up the skins along the rib joints, then cleco'ed the ribs in place. I then spent more of the afternoon prosealing and riveting the first three ribs in place.
September 5, 2006 (2 hours)
Prosealed and riveted one more interior rib. One more plus the two end ribs to go.
September 8, 2006 (2 hours)
One more rib down.
September 9, 2006 (3 hours)
Prosealed and riveted the two end ribs, including the stiffener plates and inboard bracket. In the afternoon we all went to the VAF-MN Wing picnic down in Webster. It was a great time.
September 13, 2006 (2 hours)
Bent float wire to fit in sender and fit properly in tank. Also made the fuel pickup tube and cut out the anti-rotation brackets, but still need to cut the slots at the end. The tubing cutter, fluting tool and bender I just bought all work great.
September 15, 2006 (2 hours)
Aaron and I helped Pete Howell put his wings on tonight. Bernie and his wife and son were there as well. Later I added the cuts for the intake end of the fuel pickup tube, added the missing sleeve to the flare end, drilled a hole in the inboard rib and ran the tubing for the vent.
September 16, 2006 (8 hours)
Added the nutplates to the access plate for the fuel sender. Then Prosealed over all the fittings and also added a dab where the vent tube runs thru each rib. Then I assembled it back together including cork and rubber rings around the access plate and sender. Also roughed the faying surfaces of the rear baffle and cleaned all the baffle rivets. Later in the evening I prosealed and riveted the baffle and Z-brackets on. I accidentally put one of the brackets on backwards, so I'll need to wait until the Proseal dries, drill out the blind rivets, and reattach it.
September 17, 2006 (2 hours)
Temporarily placed tank on wing. Dimpled the screw holes in the splice plate, removed the outboard leading edge section and drilled the rivet holes for the nutplates. Removed the ribs from the leading edge skin and deburred and dimpled the ribs and splice plate. Aaron and I helped Pete remove his wings now that he's got the sweep set and the rear spar drilled.
September 19, 2006
Helped Pete re-attach his left wing.
September 21, 2006 (1 hour)
Removed the backwards Z-bracket, cleaned it all up, then re-riveted and prosealed it back up. Also added proseal over the rest of the tank rivets. Drilling out the blind rivets proved easier than I thought, but I'm sure the proseal helped keep them from rotating too much. Tomorrow night I should be able to test the tank.
September 22, 2006
Set up manometer tank leak test and pressurized tank. Once fittings and access plate screws were all tight it seemed like there were no signs of leaks.
September 23, 2006 (5 hours)
Tanks don't leak! Tank pressure stayed up all night and through half of today. Deburred the edges and inside rivet holes on the leading edge skin. Removed the top wing skins and countersunk all the rivet holes in the spar. Deburred all the main rib, rear spar and J-stringer holes. Used my rivet shave bit on some of the nutplate rivets on the main spar. Drove over to Bernie's hangar to help Pete re-attach his right wing.
September 24, 2006 (1 hour)
Dressed and primed a few of the small nicks in the main spar.
September 27, 2006 (2 hours)
Deburred and dimpled the outboard leading edge skin.
September 29, 2006 (3 hours)
Dimpled the main ribs before work. In the evening I riveted the spar to rib holes that are under the fuel tank skin, then cleaned the outboard leading edge ribs, skin and splice plate in preparation for priming.
September 30, 2006 (2 hours)
Primed the outboard nose ribs, skin and splice plate. Also dimpled the rear spar and then hit each dimple with my deburring tool.
October 1, 2006 (5 hours)
Cleco'ed and then riveted ribs to outboard leading edge skin. Riveted nutplates to splice plate. Also drilled hole in skin for tie-down. Here's what both the tank and outboard skins look like attached to wing.
October 4, 2006 (2 hours)
Fabricated the pitot mounting plate stiffener angle, drilled rivet holes in the Gretz pitot mounting plate, attachment angle and wing skins. Also began drilling out the hole for the pitot mounting tube.
October 5, 2006 (2 hours)
Finished cutting and filing the hole in the skin for the pitot mounting tube. Then began deburring the J-stiffeners.
October 6, 2006 (6 hours)
Dimpled the J-stiffeners, then deburred and dimpled the top skins.
October 8, 2006 (5 hours)
Primed the wing skins, stiffeners and pitot brackets. Later I riveted about half the leading edge ribs to the spars.
October 9, 2006 (2 hours)
With the help of Tracy, finished riveting the leading edge ribs to the spar.
October 10, 2006 (1 hour)
Look - no clecos! Riveted the outboard leading edge skins to the spar. Also hung the inboard skin and wing walk doubler to the ribs in preparation for riveting the top skins on.
October 12, 2006 (1 hour)
Cleco'ed the aileron and flap brackets to the rear spar and fabricated the W925 B & C angles.
October 13, 2006 (1 hour)
Installed and torqued the tank bolts.
October 14, 2006
Built a wing cradle.
October 15, 2006 (10 hours)
Completed finished riveting the top skins to the spars and ribs in a marathon day with a lot of help from Tracy! She did a great job with the rivet gun. Even took the wing off of the jig and put it in the cradle.
April 23, 2008 (3 hours)
Since I finished the right wing bottom skins yesterday, it was time to start on the left. I was pleasantly surprised to find that I had already deburred the rivet holes, so tonight I deburred the edges and dimpled all the rivet holes.
April 24, 2008 (1 hour)
Set up the sawhorses outside so I could scotchbrite and clean the two left wing bottom skins. Then pulled them back inside, dried them off, and shot them with a coat of primer.
April 27, 2008 (5 hours)
Aaron helped me this morning with installing the conduit and pitot tubing through the left wing, grinding my Gretz pitot tube to fit into the mount, adding some nutplates to the mounting bracket that holds the small circuit board, and drilling it to the rib, and also beveling and priming the overlap part of the inboard skin. Late in the evening I riveted the inboard skin to the ribs and spars.
April 28, 2008 (3 hours)
Worked on some miscellaneous stuff before I can close up the outboard bottom skins, including the aileron bellcrank bushing, touching up and priming some minor dings and figuring out how to make the pitot to tubing run connection.
April 29, 2008 (1 hour)
Realized I hadn't shortened the brass bushing inside the bellcrank enough to allow a couple of bolt threads to stick out past the end of the locking nut. Took it apart, filed the bushing a little, regreased and put it back together and final torqued all the bolts. Also put the outboard skin back in place and am ready to start riveting.
April 30, 2008 (1 hour)
Started riveting the outboard bottom skin in place.
May 1, 2008 (2 hours)
Riveted two more bays.
May 2, 2008 (3 hours)
Finished riveting the bottom skins tonight!