Starting the construction of the wing kit is an exciting step. The wings are normally built by hanging the spar and rib assembly on a jig. Because the third stall in my garage didn't allow space for me to build both at the same time, I did all the spar and rib prep work for both wings first. Once complete, I then built the left, then the right wing, followed by the flaps and ailerons.
Drilling all the countersink holes in the spar flanges for the tank screws and nutplates is naturally nerve-wracking, as I think every builder worries about drilling too much and ruining their spar. On the other hand, fluting and deburring all the main and nose ribs (58 in all) is an endless task. I'm glad I decided to finish all of them for both wings early on.
Total Construction Time: 80 hours
May 11, 2006
My wing kit arrived today!
May 14 to 16, 2006
Inventoried the wing kit, put all the rivets and hardware into a third storage tray, doubled the length of my workbench, build long slide-out storage trays under the bench top and a wing skin storage area against the wall. All the ribs and miscellaneous parts are on the shelf in the front of the garage.
May 22, 2006 (1 hour)
Made jig for drilling countersinks for #8 screws in spar flange. Drilled first one, and it came out nice and smooth. Think this will work much better than using the platenut as a guide. Regardless, the holes look huge but my test dimple piece looks to fit nicely.
May 26, 2006 (2 hour)
Finished with 30 countersinks on the left spar bottom flange, excluding the last, angled one. The countersinks are all very consistent in size without any chatter.
May 27, 2006 (3 hours)
Finished all the rest of the countersinks for the #8 tank attach screws for both spars.
May 28, 2006 (3 hours)
Countersunk the spar flanges for the #6 access plate attach screws. Later countersunk the holes on one flange for the platenut rivets and Alodined the countersinks. Getting a weird bluish color, which I believe is due to some of the other elements in the aluminum spars.
May 29, 2006 (4 hours)
Countersunk the rest of the rivet holes for the platenuts in both spars and Alodined them. Also riveted all the platenuts to the right spar.
May 30, 2006 (1 hours)
Rivets the platenuts to the other spar.
June 3, 2006 (1 hours)
Riveted two platenuts to each spar at the most inboard points. Also tapped the 3/8" diameter holes in the two tie-down extrusions.
June 4, 2006 (2 hours)
Cut the two tie-down extrusions to length, sanded them, drilled the holes for the bolts and platenuts and Alodined them. Bought a HVLP sprayer tonight to try out with the AFS primer/sealer.
June 5, 2006 (1 hours)
Shot the two tie-down extrusions with AFS Primer/Sealer using my HVLP sprayer. Really liked using it. Came out pretty good for never using a sprayer.
June 6, 2006 (1 hours)
Bolted the tie-down extrusions and the aileron bellcrank brackets to the spars. First time I got to use the torque wrench. I was surprised how little torque is the right amount.
June 8, 2006 (1 hours)
Basically done with the first steps of the main spars. Pulled out the parts for the rear spars which seem puny compared to the main spars. Did the initial sanding of the long edges of the two W907A spar members.
June 9, 2006 (2 hours)
Final sanded the edges of the two long W907A spar members. Also deburred the W907C, D and E doublers.
June 10, 2006 (4 hours)
In the morning I deburred the edges of the W907B doublers. In the evening I drilled the holes in the W907D and E doublers and then cut the oblong holes to match the ones in the spars.
June 11, 2006 (2 hours)
Match drilled and countersunk the holes in the W907B and C doublers, then dimpled the flanges of the spar and the W907D and E doublers. Ready to prime the rear spare parts.
June 14, 2006 (1 hours)
Cleaned all the wing spar assembly parts using the AFS Etch/Cleaner.
June 15, 2006 (1 hours)
Sprayed AFS primer/sealer on the wing spar assembly parts.
June 17, 2006 (2 hours)
Riveted the W907B, C and D doublers to the W907A spars.
June 18, 2006 (4 hours)
Bought a die grinder this morning then deburred all the rib holes. Later I went over all the holes again to final deburr them.
June 19, 2006 (2 hours)
Spent a couple hours touching up a few of the holes in the ribs. Then I deburred the edges of ten of the main ribs. Many more to go.
June 20, 2006 (3 hours)
Spent three hours deburring the rest of the edges of the main ribs. Next up are the nose ribs.
June 21, 2006 (2 hours)
Spent two hours deburring the edges of half the nose ribs.
June 22, 2006 (2 hours)
And spent another two hours deburring the edges of the other half of the nose ribs. Still have all the tight corners to deburr, then later fluting.
June 29, 2006 (1 hours)
After a week break for scout camp and a few days to recover from scout camp, back at it. Deburred the notches and corners on four of the main ribs.
July 1, 2006 (1 hours)
Finished up six more.
July 2, 2006 (5 hours)
Finished up the remaining 20 main ribs.
July 3, 2006 (6 hours)
Finished half of the nose ribs. Then later finished the other half. Deburring ribs is done!
July 4, 2006 (3 hours)
Fluted all the ribs today.
July 5, 2006 (3 hours)
Spent a little time trying to get the nose rib holes lined up a little better. Finally decided to put them aside and start putting together the wing assembly. Now it's starting to look like wings!
July 9, 2006
Been busy building the shed out back to clear room for my wing jig. Also put up the two posts for the wing jig.
July 14, 2006 (3 hours)
Match drilled the rib to spar holes and disassembled the parts.
July 15, 2006 (5 hours)
Straightened all the main rib flanges to 90°. Deburred the misc. holes in the webs. Also drilled a few of the holes that weren't match drilled.
July 16, 2006 (8 hours)
Deburred the match drilled holes in the flanges. Also drilled out the ¾" holes for the wiring conduit. Then spent the rest of the time cleaning and priming all the main ribs.