Wings
Wing Wrap-up – Part 1
Manufactured -02L and -02R flap fairings from scrap aluminum stock. Bent with tabletop bending brake. Will flight test before installing onto fuselage. Aimed landing lights in full down position per Duckworks instructions then cleaned and reinstalled landing light lenses. Hours Worked: 0.80
Pitot Installation – Part 2
Did some rough trimming of the RH side fuselage side panel to verify routing path of pitot/aoa tubes. Disconnected RH rudder cable to ensure all bundles were behind it then reconnected cable to rudder pedal. Drilled 1/2″ holes through fuselage vertical channel and installed rubber grommets. Routed lines though grommets then up RH side of…
Pitot Installation – Part 1
Leveled fuselage then temporarily installed pitot mount into RH wing to calculate spacer size needed to level pitot tube. Made 2 0.125″ spacers (0.25″ total) out of 0.125″ aluminum sheet to place under back side of pitot tube mount. Installed mount into RH wing, checked levelness, then installed screws. Installed pitot mast into mount and…
Wing Installation – Part 1
With help, mounted left and right wing assemblies onto fuselage. Attempted to add weatherstripping on inside edges of wings but there wasn’t enough clearance; will likely seal gaps with tape later on. Before sliding wings fully together, connected wing root connectors and pitot/AOA connections. Opted to use drilled hardware and cotter pins for wing bolt…
Final Wing Assembly
Removed wings from wing stand and set onto saw horses. Assembled aileron push rods and filed thrust bearings down for 0.01″ clearance between bushing and bell crank plate and installed assembly onto LH aileron. Slightly enlarged counterweight opening in rear spar for bolt clearance then attached LH aileron to wing with piano hinge rod. Drilled…
Aileron Balancing
Assembled paint fixture to hang ailerons from. Suspended RH aileron from fixture and bolted lead counterweight onto bracket. Checked levelness per plans and did not need to remove any material. Repeated process for LH aileron and drilled one 3/16″ hole on top of lead counter weight approximately 1/2″ deep to achieve balance. Ailerons now complete…
Wingtip Installation
Installed nutplates for wingtip light fairings onto wing tips and riveted wingtips onto wings with AAP-42 aluminum rivets. After wingtips were installed, sanded rivets in preparation of paint. Hours Worked: 1.30
Wing Tip Finishing – Part 2
Removed wing tips from wing after letting SuperFil cure. While not the most elegant (or clean) epoxy job, it did take up the gap pretty well. Removed packing tape from edge of wing and lightly reshaped the edge of the wingtips. Removed ailerons and faps from the wings to prepare for paint. Hours Worked: 0.90
Wing Tip Finishing – Part 1
Began prepping wingtips and tip light fairings for paint and final finishing. Located tip lights onto wing tip light fairings and drilled wire pass through hole and mounting screw holes; tip lights will attach to fairing with Dynon panel screws and elastic nuts. Located tip light fairings on the wing tips by aligning center of…
Wing Root Doublers – Part 2
Measured wing root doubler trim distances off of wing skin at each rivet hole and transferred measurements onto inside edge of wing root doublers. Trimmed excess material off with snips then deburred edges. Clecoed wing root doublers onto wing and verified clearance from fuselage sides was between 1/32″ and 1/16″. Hours Worked: 1.89
Wing Root Doublers – Part 1
Slid wings out from fuselage (one at a time) and reinstalled wing root doublers with clecoes. Marked current edge of doublers onto wing skins with sharpie. Removed doublers then slid wings back into spar tunnel and pinned into proper place. Set wing doublers onto wings and slid them flush with fuselage side skins. Marked a…
Wing Pushrod Installation – Part 1
Removed aileron bellcrank access covers from wings and inserted C03-01 main aileron pushrods into wings. Attached to aileron bellcrank with AN3 hardware and castle nut. Installed C03-03 flap pushrods onto flaps with AN4 hardware. Hours Worked: 0.98
