Wings - 5

July 28, 2013 5.5 hours, 167.0 hours total. Got about 5.5 hours in on the project over the weekend. I'm falling behind my self appointed schedule. I should be at the 230 hour point, so I'm behind schedule by about 9 weeks. But, life is busy, plenty going on and its important to keep things in balance to keep everyone happy. Happy wife, happy life!

At any rate, this weekend I finished assembly of the main spar. This included attachment of the 10 each wing rib brackets, outboard rib trim and finishing up of the required spar riveting.

After completing that, I spent time assembling the flaperon flange brackets and stub spar assembly.

Ready to rivet the flange brackets. There are five brackets per spar per side. The cleos also  temporary hold the tabs on the opposite side of the spar.

 The outboard spar tab/flange in position to rivet.

 The left and right stub spar assemblies with 8 AN470-8-8 rivets and 3 AN426-4-4 rivets. The remaining 6 bracket holes get riveted at a later point in the assembly.

 Underside of the assembly. The three tip rivet holes are countersunk on bothe side.

 Flange bracket assembly process.

 Four completed flaperon hinge brackets, two per side.

 Two flaperon hinges with sandwiched bearings, one per side.

 Left and right aft spar assembly ready for debarr and sanding.

Wings - 4

July 8, 2013, 5.0 hours, 161.5 hours total to date. Yes it's Monday, and no I'm not retired. I took a day of vacation so I could enjoy a three day weekend. That gave me some garage time to work on the wing spar components. Today I continued with the flaperon flanges [ W-1216 hinge bracket assemblies pictured in yesterdays post], W-1212 Hinge Assembly and the rear spar doublers. Primarily more deburring and sanding and a couple more countersinks. Oh yea, I also prepped the tip attach angles. So, to date I've got just about everything prepped for the spar assembly. I'll prime parts next weekend and then assemble those components.

Pictured below are the W-1212 Hinge Assemblies, left and right. You will see the flange brackets, hinge plate that holds the Bearing Com 3-5. 

 Illustration of how everything fits together. 

 Temporary assembly, minus bearing prior to any deburring or sanding.

 Sanding complete and countersinks installed for AN426AD4-6 rivets. Each side of the bracket. left/right is countersunk in two locations.

 These are the left and right doublers that attach to the left/right rear spar webs.

 Illustration of the rear spar and rear spar assemblies.

 Piece-part progress to date, pictured in the next two photos.

Wings - 3

July 7, 2013 5.5 hours- 156.5 hours total. I got about 3.5 hours in yesterday and 2 hours this morning. I feel like I'm back into the project after a short break. Only got a few hours in yesterday because I had a plane reserved for 7:00 in the morning. This time of year it's best to get up in the relatively cool morning air. The heat takes a little joy out of summer flying. I had a great flight yesterday. Not a single bump. The air was as smooth as glass. Just 1.2 hours in the sky, but a great time.

So, between yesterday and today I've done primary work on the left and right spar stubs and actually started work on the flaperon brackets.

Pictured below is the Spar Channel with the Spar Doubler Clecoed. The combined subassemblies make up the Spar Stub assembly.

 The first operations include countersinking the spar channel flanges. There are 42 #30 holes on each flange side, equaling 84 holes that need to be countersunk per channel, or 168 total. These are 120 degree countersinks. Holes are countersunk to a depth to create a 0.25" outside diameter at the surface of the flange. 

In addition to the flange countersinks, there are three each 100 degree #40 holes that are countersunk on both sides of the doubler and channel.

Observe- 100 degree countersinks, three places in the backside of the channel.

Picture of the channel countersinks below.

 The Spar Channel and the matching doubler.

 The assembly. 

In addition to the countersinking I performed all the debur operations and smoothed and sanded all the edges. Once I've gathered a sufficient quantity of components, I'll prime and then assemble. For the time being I'm finished with these assemblies.

Then it was into the the Flaperon Brackets. There are two brackets per wing, with left and right subassemblies.

 Shown below are the four brackets cleocoed together, left and right assemblies. The work ahead is, you guessed it, debur and sand then rivet once primed.

Wings - 2

Well Happy 4th of July! 3.5 hours- 150.5 hours total on the project. Finally made it back out to the garage and I've officially started the wing build. First section of the build is the spar assembly. There are 22  W-1206 V rib attach brackets and the W-1201 rib doublers that needed to be separated, deburred and sanded smooth. After that it was time to tap the 3/8 - 16 wing tie downs. 

I've got to figure out the summer wing build schedule. Since June 1 we've had non-stop +100 degree days. The garage was at about 88 degrees with the cooler running. I was able to work in the garage until the temperature hit 90, and that was enough for one day.

This is an example of the W-1206 V angle bracket prior to filing and smoothing the ends.

Close-up of the same bracket- again there are 22 of these brackets.

The brackets in various degree of finish

And this is the W-1201 doublers prior to separation.

And here is an example of the wing tie-down fitting, post tap. Both ends of each tie-down fitting on each spar get tapped with 3/8 16 treads,

 Strange photo of the two spars from the outboard end.