01 Feb 2007 - 6.8hrs
I've decided to build both wings at the same time. Due to limited building space, I will have to move my tables out of the way in order to build the wing jigs, so I'm going to build the internal wing parts first since they are built on a table. Start with the aileron hinge brackets.
02 Feb 2007 - 4.5hrs
Start on aileron bellcrank brackets
03 Feb 2007 - 6.8hrs
Rivet aileron bellcrank brackets, start on pulley brackets and flap bellcrank crackets.
04 Feb 2007 - 3.5hrs
Finish up flap bellcrank crackets. EAA Tech Counselor inspection (2 hours). All is well! :-) I was pretty psyched that the possible solutions I had come up with for a few questions I had were matched by the suggestions by the Tech Counselor.
06 Feb 2007 - 2.8hrs
Inboard pulley brackets.
07 Feb 2007 - 2hrs
Outboard pulley brackets.
09 Feb 2007 - 0.5hrs
10 Feb 2007 - 4.25hrs
Start flap bellcranks.
11 Feb 2007 - 5.75hrs
Finish flap bellcranks. Start flap pulley brackets.
12 Feb 2007 - 2.75hrs
Trim flap track ribs - they don't fit quite right. The ribs extend down too far into the flap track pathway, and have to be corrected. Easy work for a die grinder... :-) Drill, deburr, clean.
14 Feb 2007 - 1.6hrs
Clean and prime flap tracks.
Start designing wing jig.
16 Feb 2007 - 3hrs
Start of the Wing Jig Major Project (or Wing Jig Hell as I've been calling it).
I want to build both wings at the same time, so I am building a 4 post wing jig, 2 posts for each wing. Lowell Boaz, a Glastar builder in VA gave me two 4 inch by 4 inch aluminum posts that he had used in his wing jig, and I found a local scrapyard that had two more posts, plus some other C frame and angle aluminum.
17 Feb 2007 - 4.25hrs
18 Feb 2007 - 2.8hrs
19 Feb 2007 - 2.5hrs
20 Feb 2007 - 2.5hrs
23 Feb 2007 - 2.7hrs
24 Feb 2007 - 5.1hrs
25 Feb 2007 - 4hrs
26 Feb 2007 - 2hrs
27 Feb 2007 - 2.5hrs
03 Mar 2007 - 5.5hrs
05 Mar 2007 - 3.2hrs
Finish wing jig and support brackets!!!!! 40.5 hours in total, not counting the time I spent outside of the shop buying parts and such. What a PITA!
After looking back over this, there is no doubt in my mind that building this wing jig has been the most complicated, difficult, and frustrating part of this airplane project so far. The tolerences must be tight so as to not have any twist in the wing, and this is difficult to accomplish when you are building a structure that is 16 feet long, 8 feet high, and you are trying to make things very exact and straight. I have things generally within 1/32 of being "right", but it was not without a certain amount of cursing and re-doing things a few times over.
06 Mar 2007 - 2hrs
Mark wing parts.
07 Mar 2007 - 0.7hrs
08 Mar 2007 - 1.75hrs
Wing root ribs.
09 Mar 2007 - 1.6hrs
10 Mar 2007 - 6.5hrs
Left root rib.
11 Mar 2007 - 3hrs
Right root rib.
13 Mar 2007 - 1.9hrs
Trim doublers in root ribs. Clean for priming.
14 Mar 2007 - 1.2hrs
Prime.
15 Mar 2007 - 2.7hrs
Rivet left root rib..
16 Mar 2007 - 0.5hrs
Make shims for ribs. This is the "blanked out" note that is in the manual.
18 Mar 2007 - 7.2hrs
Rivet right root rib. Cleco ribs to left wing spars.
28 Mar 2007 - 2.2hrs
Cleco ribs to right wing spars.
29 Mar 2007 - 1.3hrs
30 Mar 2007 - 2hrs
Drill rib holes up to #30 in right wing.
31 Mar 2007 - 4.3hrs
Drill rib holes up to #30 in left wing.
02 Apr 2007 - 2hrs
Get parts and assemble strut attach beams.
03 Apr 2007 - 2hrs
Drill left strut attach beam.
04 Apr 2007 - 2.5hrs
Drill right strut attach beam. Place beams in spars and drill attach holes. Position left wing outboard leading edge.
11 Apr 2007 - 2.8hrs
Ream the two large 3/8 holes in strut beams. Debur, clean, and prime both strut beams.
12 Apr 2007 - 1.2hrs
Assemble strut beams.
26 Apr 2007 - 1.75 hrs
Finish riveting flap tracks.
27 Apr 2007 - .8 hrs
Start putting stuff on the aft spar.
28 Apr 2007 - 2.8 hrs
Put more stuff on the aft spar.
29 Apr 2007 - .8 hrs
And yet more stuff on the aft spar.
30 Apr 2007 - 2.3 hrs
I sense a trend here...
02 May 2007 - 2 hrs
Flap bellcrank, left wing.
03 May 2007 - 2.5 hrs
Angles for flap bellcrank.
04 May 2007 - 1.5 hrs
06 May 2007 - 5.5 hrs
Mount flap pulleys. Fabricate flap reinforcement angles.
12 May 2007 - 3.5 hrs
Bolt strut beams in place. Left wing outboard leading edge.
13 May 2007 - 3.5 hrs
Right wing outboard leading edge, and left wing center leading edge.
14 May 2007 - 2 hrs
Left wing inboard leading edge.
15 May 2007 - 2 hrs
Right wing center leading edge and inboard leading edge.
16 May 2007 - 2.3 hrs
Finish right wing leading edge, start spar caps.
19 May 2007 - 3.5 hrs
Finish spar caps, prepare for leading edge drilling. Drill left wing top leading edge holes.
20 May 2007 - 2 hrs
Drill left wing bottom leading edge holes, and nose ribs.
21 May 2007 - 2.5 hrs
Drill right wing top leading edge.
22 May 2007 - 2.25 hrs
Drill right wing bottom leading edge, nose ribs. Position left wing outboard top skin.
25 May 2007 - 3.25 hrs
Position left wing center and inboard top skins.
26 May 2007 - 1.25 hrs
Misc tinkering.
27 May 2007 - 4.5 hrs
Position right wing outboard, center and inboard top skins, right wing outboard and center bottom skins, left wing outboard and center bottom skins, and left wing inboard bottom skin.
28 May 2007 - 2 hrs
Position right wing inboard bottom skin. Take wing skins off for leading edge trimming.
02 Jun 2007 - .75 hrs
Position marking.
03 Jun 2007 - 1.75 hrs
Debur main skin edges, trim left outboard leading edge.
04 Jun 2007 - 2.25 hrs
Mount left wing outboard leading edge and outboard top and bottom skins, trim leading edge. Trim center leading edge, mount center top and bottom left wing skins.
05 Jun 2007 - 1 hrs
Trim inboard left leading edge, mount inboard top and bottom skins.
06 Jun 2007 - 2.25 hrs
Trim right wing outboard and center leading edge, mount top and bottom outboard and center main skins.
12 Jun 2007 - 2 hrs
Trim right wing inboard leading edge, mount top and bottom inboard main skins. Drill left wing outboard top main skin.
13 Jun 2007 - .75 hrs
Remove plasttic from top left skins.
16 Jun 2007 - 4.25 hrs
Finish removing plastic and drill left wing top forward spar and ribs.
17 Jun 2007 - 2.5 hrs
Finish drilling left wing top main skin. At step 23. Started drilling left wing bottom side of forward spar.
18 Jun 2007 - 1.25 hrs
Finish drilling left wing bottom side of forward spar.
20 Jun 2007 - .75 hrs
Continue drilling left wing bottom skins.
21 Jun 2007 - 1 hrs
Finish drilling left wing bottom skins.
23 Jun 2007 - 1 hrs
EAA Tech Counselor inspection.
25 Jun 2007 - 1.25 hrs
Start drilling right wing top side of forward spar.
26 Jun 2007 - 1.25 hrs
Finish drilling right wing top side of forward spar.
14 Jul 2007 - 1 hr
Mark center lines on hat sections.
It is starting to get WAY too hot to work in the shop - time to do something about it. See the "Preparing" section for the cool (literally) insulation that I installed.
29 Jul 2007 - 2.5 hrs
Finish drilling bottom skins on the right wing.
30 Jul 2007 - 1.3 hrs
Start the layout and position of the hat sections.
19 Aug 2007 - 5.25 hrs
Drill the hat sections. Mark center lines on stiffeners. Drill bottom of right wing to #30 size.
20 Aug 2007 - 2 hrs
Drill bottom of left wing to #30 size (end of Step 36).
21 Aug 2007 - 0.5 hrs
Review pitot tube and static port installation instructions. I'm using the Dynon heated pitot tube.
22 Aug 2007 - 2 hrs
Drill bottom wing stiffeners.
23 Aug 2007 - 1.5 hrs
I found another error (strictly speaking, an omission) in the installation manual. It does not mention that you have to drill #30 holes in the second rib in the double rib at station 69. I marked the holes to match the first set, and drilled them to #40 for the initial fit. Be careful of the stiffener - the pre-made hole does not line up with it, so you the holes that goes through the skin, second rib, and the stiffeners will be offset slightly. I missed this on one of the skins... grrr.
25 Aug 2007 - 3.75 hrs
Mount top skins, remove bottom skins, position left wing top hats and stiffeners and drill them.
26 Aug 2007 - 2 hrs
Drill right wing, top hats and stiffeners.
27 Aug 2007 - 1.5 hrs
Drill top right wings skins up to #30.
28 Aug 2007 - 2 hrs
Drill double ribs up to #30, and start left wing #30 drilling.
29 Aug 2007 - 2 hrs
Finish drilling left wing up to #30.
15 Sep 2007 - 6.3 hrs
Drill root ribs to #30, and make the countersink holes in the root ribs for the mounting screws. Fabricate shims for the ribs to fill the gap created by the spar doublers between the spar and the ribs for the center holes of the ribs.
17 Sep 2007 - 1.5 hrs
Start removing plastic covering from the skins in preparation for deburring.
20 Sep 2007 - 0.25 hrs
Start removing clecos.
22 Sep 2007 - 3 hrs
Plastic removal, debur top of top skins.
26 Sep 2007 - 2.5 hrs
Debur left leading edge skins and left nose ribs.
30 Sep 2007 - 5.4 hrs
Dimple left leading edge skins and nose ribs. Debur and dimple right leading edge skins and debur right nose ribs 1-6.
02 Oct 2007 - 3.3 hrs
Debur and dimple right nose ribs 7-17. Debur inside of top left skins and internal wing parts.
03 Oct 2007 - 2.2 hrs
Debur left bottom skins and start deburring right top skins.
04 Oct 2007 - 2.25 hrs
Finish deburring right top skins and start deburring right bottom skins.
05 Oct 2007 - 0.5 hrs
Finish deburring right bottom skins.
06 Oct 2007 - 6.5 hrs
Dimple left top and bottom skins, and right top skins.
08 Oct 2007 - 1.1 hrs
Debur left wing rib, flap, and aileron cove ribs, and holes common to wingskin, and the top of the right wing ribs.
15 Oct 2007 - 1.2 hrs
Debur bottom of right wing ribs, right wing flap and aileron cove ribs, and left and right top hat sections.
16 Oct 2007 - 1.5 hrs
Debur bottom stringers and hat sections. Start dimpling left wing ribs, flap and aileron cove ribs.
17 Oct 2007 - 2.8 hrs
Dimple top stringers and hat sections.
18 Oct 2007 - 1.5 hrs
Dimple left bottom ribs, right top and bottom ribs.
20 Oct 2007 - 1.5 hrs
Start countersinking spar for the left outboard leading edge skins.
23 Oct 2007 - 1.5 hrs
Countersinking spar for the right outboard and center leading edge skins.
27 Oct 2007 - 4.1 hrs
More countersinking...
28 Oct 2007 - 2.75 hrs
Debur inside of spar wing skin holes.
30 Oct 2007 - 1.75 hrs
Fabricate shims for forward end of ribs and spar beam.
31 Oct 2007 - 2.5 hrs
Permanently mount the strut beam to the spars, torque nuts, and mark with orange goo.
01 Nov 2007 - 1.5 hrs
Debur spar caps, left flap ribs (holes common to the spars).
08 Nov 2007 - 2 hrs
Debur right aileron and flap ribs, some left wing ribs (holes common to the spars).
09 Nov 2007 - 1.8 hrs
Debur left wing ribs (holes common to the spars) and left spars.
10 Nov 2007 - 2 hrs
Debur right wing ribs (holes common to the spars) and right spars. Start deburring the hat section edges.
11 Nov 2007 - 2.5 hrs
Finish deburring!!!! Do some primer touch-up on some of the internal wing parts.
12 Nov 2007 - 2 hrs
Bolt aileron pulleys to spars, prime the angle brackets used on the bellcranks.
18 Nov 2007 - 1.7 hrs
Start to rivet the aileron hinges and bellcrank (left wing) to the spar.
22 Nov 2007 - 3.1 hrs
Finish riveting left aileron bellcrank to the spar, mount flap pulleys.
23 Nov 2007 - 4 hrs
Clean and prime some wing parts.
24 Nov 2007 - 6.5 hrs
Touch up priming, clean and prime more parts.
25 Nov 2007 - 5.25 hrs
Rivet left flap bellcrank, right flap bellcrank, and right aileron bellcrank.
27 Nov 2007 - 1.25 hrs
Prime left wing ribs, hat sections, and spar caps.
01 Dec 2007 - 5.75 hrs
Prime and clean parts, right wing ribs, hat sections, stringers. Touch up priming on some parts. Mount left wing ribs.
02 Dec 2007 - 4.75 hrs
Prime remaining hat sections, stringers, remaining parts. Mount right wing parts and start riveting.
05 Dec 2007 - 0.25 hrs
Organize primed parts.
08 Dec 2007 - 3 hrs
Rivet outboard half of left wing internal parts.
09 Dec 2007 - 3.75 hrs
Finish riveting left wing internals.
03 Jan 2008 - 1.5 hrs
Start riveting right wing internals.
05 Jan 2008 - 4.5 hrs
Finish riveting right wing internals.
07 Jan 2008 - 0.5 hrs
Clean nose skins in preparation for priming.
08 Jan 2008 - 2 hrs
Dimple right wing bottom skins.
09 Jan 2008 - 2 hrs
Start countersink spar.
11 Jan 2008 - 2 hrs
Finish dimpling right wing skins. Clean bottom wing skins. Prime bottom wing skins.
12 Jan 2008 - 1.25 hrs
Prime leading edge outboard skins (left and right wings).
13 Jan 2008 - 5 hrs
Primer touchup. Finish countersinking spar. Cleco nose ribs to leading edge skins, start riveting. Prime countersunk holes.
18 Jan 2008 - 2 hrs
Rivet nose ribs to left inboard leading edge. Cut slot for flap track left inboard skin.
19 Jan 2008 - 1.5 hrs
Finish cutting slots for both flap track.
21 Jan 2008 - 3.75 hrs
Incorporate manual revisions into main manual (ANORs, etc).
03 Feb 2008 - 1 hrs
Reference SBs to main manual.
26 Oct 2008 - 1.5 hrs
Setup wing jig in new shop.
28 Oct 2008 - 1 hr
Vertically level wing jig.
30 Oct 2008 - 1.25 hrs
Rough align wing jig, prepare to move wings to jig.
01 Nov 2008 - 2 hrs
Put wings in jig. Build center support for left wing.
06 Nov 2008 - 3 hrs
Build right wing center support. Level both wing jigs in all three dimensions.
12 Nov 2008 - 2.5 hrs
Verify level of wing jigs. Put down rubber interlocking flooring. Start building paint booth.
13 Nov 2008 - 2 hrs
Finish paint booth. Touch up small parts.
15 Nov 2008 - 4 hrs
Prime bottom wing skins. Start to clean moving tape off leading edge skins.
16 Nov 2008 - 5 hrs
Clean tape residue off leading edge skins. Start riveting leading edge ribs to skins.
18 Nov 2008 - 1.75 hrs
Continue riveting leading edge skins to ribs.
19 Nov 2008 - 1.5 hrs
Finish riveting leading edge skins to ribs. Prime leading edge skins where they overlap.
23 Nov 2008 - 6.25 hrs
Join leading edges together. Mount leading edges on spars. Prep wing skins for mounting (prime where skins overlap).
30 Nov 2008 - 5 hrs
Rivet right wing nose ribs to spar. Start riveting left wing nose ribs to spar.
13 Dec 2008 - 3.25 hrs
Finish riveting left wing nose ribs to spar. Start riveting leading edge skins to spar.
30 Dec 2008 - 3 hrs
Start riveting left nose skin to spar.
31 Dec 2008 - 2 hrs
Finish riveting left nose skin to spar.
02 Jan 2009 - 6.25 hrs
Rivet right nose skins to spar. Open up flap track holes in top skin. Route out flap track support angles for .30 clearance.
04 Jan 2009 - 4.25 hrs
Page 157, Fig 84 should be ".30 from track edge", same as ANOR for page 130, Fig 67.
07 Jan 2009 - 2.5 hrs
Remake flap track reinforcement angles. Apparently didn't make them big enough the first time, as I can't get the appropriate clearance for the rivets.
10 Jan 2009 - 1.25 hrs
Finsh the new flap track reinforcement angles. Make placement of them on the wings. Drill right wing inboard flap track reinforcement angle.
25 Jan 2009 - 4 hrs
Finish drilling flap track reinforcement angles. Prime. End of step 64.
31 Jan 2009 - 4 hrs
Cleco right and left bottom wing skins. Right wing bottom skin ready to rivet.
08 Feb 2009 - 0.25 hrs
01 Mar 2009 - 5.75 hrs
Start riveting right wing bottom wing skins with Leo.
14 Mar 2009 - 5.75 hrs
Finish riveting right wing bottom wing skins with Leo.
21 Mar 2009 - 4 hrs
Start riveting left wing bottom wing skins with Leo.
29 Mar 2009 - 8 hrs
Finish riveting bottom wing skins with Leo. Finish riveting flap bracket attach angles. Wings are done to the Quick Build stage!
END OF BOOK ONE!!!!!
