We spend four hours on the right wing. The fiberglass and metal Horner tip were drilled into place along with the outboard portion of the wing root skin.

For the (L) angle that helps holds the tip, the best thing to do is to predrill the portion that contacts the spar extension, and then back drill it into place. Otherwise it would be to awkward to get the drill into that portion of the wing.

The fiberglass fit much better this time, but I had to fabricate a small extension to get the nose skin into a safe edge distance on the most rounded part of the tip.

The area of overlap between the fiberglass was much better and no extension was needed this time.

When you layout the wing root skin, do yourself a favor and actually use the corner of the metal as your ( 0, 0 ) point.

This time when doing the rough trim I was smart enough to use the Olfa knife which saved a huge amount of time.



Project Status:
Wings: ~155.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h, 4h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~257h

Over the weekend only a little building got done due to camping, and then a light cold.

First last week, there was one hour of building that included drilling some holes out to A4s and getting the lower tip angle positioned, but not drilled.

The skin had a slight bubble to it that just got pushed around. The solution was to drill out the rivets holding the outer most lower skin to the trailing edge skin, drilling the lower angle into place, and then enlarging the previous holes to A5s. This did not eliminate, but drastically reduced the bubble.

Monday nights session was only two hours and included drilling the top and lower angles into place and preliminary positioning of the fiberglass tip.

Project Status:
Wings: ~151.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~253h

It was a two hour long battle to get the fuel send perfectly seated into the tank.

Several issues to avoid

1. Zenith shipped an extra seal, the one I used was a worse fit than the other.
2. The ohm meter had a calibration wheel that I forgot about, and I was confused to why the readings were so strange
3. Make sure that hole is circular! If not you may need to smooth it out to keep the bolt from using the tank as it's thread.

Most of all, enlarging the hole is a slow process. I also got the grounding setup on the tank,

Project Status:
Wings: ~148.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~250h

Sunday we spent five hours in a building sprint. The lessons learned from the left wing allowed for rapid progress on the right wing.

The first, smaller cut for the fuel sender was made, the fuel tank channels were drilled into place, the fuel drain hole was made, and the fuel feed hole was also made.

For the fuel drain hole I attempted something different. On the left wing I measured and was off. For this wing I place the tank in the wing and felt where the drain pushed against the wing, and marked that spot.... and was off. So I measure and hit it on the spot, creating two holes. I created a patch that rested on the inside to close the hole up.

The fuel sender hole is just a rough cut and needs to be enlarged.

Luckily the fuel filler template was 100% reusable for this wing. Due to the CNC pre-drilled holes, I was able to just flip the template over. I undercut the hole intentionally and then enlarged the hole with a half round file for a near perfect fit.

For comparison the same amount of work for the left wing took about twelve hours.

Project Status:
Wings: ~146.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~248h

We spent about three hours on the wings Saturday night. Only one hour was spent on construction. The other two hours were spent on the workshop.

First up was bending the wing root skin and drilling it. This is harder than it should be.

First I bent the trailing edge as indicated in the manual, but the skin is too stiff. I attempted using duct tape to hold the skin, but that didn't work.
After un-clecoing the skin, I made a few slight bends in the skin to make it easier to round the tip ribs. Then using an assistant, the holes were drilled.

The left wing is now ready to be inspected and prepared for final riveting!

Project Status:
Wings: ~141.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~243h

I spent an hour bending the root skin over. This is a slow process if you want a good fit. It took lots of incremental trimming and filing.

Once a fit +/-3mm was achieved between the main top skin and the root skin, I used a rasp on the root skin to get everything flush. This worked very well.

All that is left is for the skin to have the bottom bent and drilled, then it goes on the wall waiting for inspection.

Project Status:
Wings: ~140.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~242h

Two hours were spent fabricating tools and drilling the wing root skin into place.

The new "strap duplicator"/"hole finder" is made from two old worn out saw blades. On the free end a partially pulled rivet is trimmed so the nail is only a few mm long, and the head is then filed down to reduce parallax. The flaw with my new design is that the pointy "finder" gets drilled out after a few uses and then requires replacing.

Getting the skin drilled properly was a fairly easy task for three sides. The line that abuts the first rib, the spar doubler line, and the rear channel lines were all easy.

The pilot holes on the root rib side are off by about .25mm, so when the holes are enlarged to A4 everything should be OK.

I think a better method would be to pre-drill only a few holes, use the hole finder on those, and then extrapolate the line, pre-drilling the root skin and then back drilling into the root rib.

Project Status:
Wings: ~140.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~242h

I spent another hour on the root wing skin... this time laying out the correct side. After giving it a rough cut and reading over the directions, I decided I need a new tool. The hole finder I fabricated is not the correct type. Mine was under the assumption that the existing hole was accessible from beneath, also it was way to short.

This wing is getting close!

Project Status:
Wings: ~138.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~240h

Another two hours of progress...

First the wing root angle angle was crimped trimmed, drilled and placed.

Next I carefully measure the wing root skin. This took forever... only to figure out that I measure for the right wing... and I'm working on the left wing.

At least work wasn't lost.

On Monday I will measure for the left wing.

Project Status:
Wings: ~137.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~239h

Not satisfied with the edge distance between the fiberglass and aluminum of the Horner tip, I made a fix. Using some of the newly discovered extra aluminum packed in the crate, I made what is essentially a splice plate to extend the aluminum. It works really well and can not be seen since I have it tucked underneath the fiberglass.

I also fit the left wing's position lights into place. This was simpler than I expected. I made a template out of a box laying around. For the larger hole I used the unibit for an initial 7/8th" hole, enlarging it was a rasp for a perfect fit.

The light itself is of a different size than Zenith's so it has a bit of overhang, but does not look bad.

In total, about three hours were spent on Saturday.

Project Status:
Wings: ~135.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~237h

An hour was spent getting the wing tip cover into place and drilled. On the next wing, my process will be to place the wing tip cover BEFORE the fiberglass tip to make sure I can get a good edge distance on the Horner part.

Zenith precut the wing tip covers giving you zero amount of play or trim. The quick build CNC parts can be a blessing and a curse.

Project Status:
Wings: ~132.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~234h

I spent two hours getting the fiberglass wing tip fit as good as possible. It is not a perfect fit, and I decided to shim a bit on the leading holes, but the fit is not poor. The (L) angle that attaches to the spar extension was also cut and drilled into place. The manual suggested 250mm for the piece, but then I would not have had any overlap. 280mm turned out to be the magic number. 285 or 290 may have also worked with some trimming.

These tips are notorious on the Matronics list, so I feel like I almost got off easy.

What really would help ( LISTEN UP ZENITH!!! ) would be to ship the tips with flanges that are at least another 10mm.

I could get the wing tip flush, but I would not have had anything to drill into!

Project Status:
Wings: ~131.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~233h

I spent three hours and completed ALL of section 6A. The top and bottom tip angles were both crimped and drilled into place. The wing skins ( top & bottom ) were trimmed. I even placed in the fiberglass tip for a test fit.

A big thanks to Brian who lent me the fluting pliers on short notice!

Project Status:
Wings: ~129.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~231h

I spent about four hours on the wing today before getting blocked. We put the nose skin back on ( I can't wait to not have to ratchet strap anything again ) The top and nose skin were drilled to together on the outboard side along with the spar extension. The slat supports were also drilled into place.

The wing tank stills needs to be tested, but I want to wait until my Jeep's tank needs a little fuel.

The blocking issue is the fluting / crimping that needs to be performed on some extrusion so the wing tip can be placed. It's amazing what extent some of the prefabrication on the CH-701 is, providing predrilled skins, assembled spars, ect... but in the same breath expect you to flute extrusion without even telling you "oh, by the way... buy a pair of fluting pliers" is just strange and inconsistent.

So I attempted to make a pair with some wood... that didn't work out to well. That excursion took a few hours. Hopefully I can find a pair to borrow... that or UPS will make a ton on overnight delivery from me.

Is it just me, or does the AMD Patriot ( aka Ch750 ) look more like a Cessna than the Cessna 162 Sky Catcher? And yes... I'm drooling over the 162... and yes I want to be the first to fly one when they make their way up here.

Project Status:
Wings: ~126.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~228h

I only spent two hours on Saturday, but they were a productive two hours. The ground wires for the fuel tank and sender were attached and crimped.

Also I decided after much debate to run the PVC conduit through the tip ribs taking advantage of their tooling hole to secure the PVC. The root tip rib will need to have it's tooling hole expanded slightly to fit the wire, and a grommet will have to be added.

The top skin had the filler cap hole cut. I intentionally cut a slightly larger hole than I needed, and I'm glad I did. The filler cap is just touching one edge of the hole. I'm not sure what to do about the small gap in the skin.

While looking for my wire crimper I found a scratch built CH-801 that was first started while I lived in Texas. It was finally finished a few years ago and is in good shape for being packed away and moved across the country a few times.

The wings, nosebowl, rudder and stabilizer had all been removed. There are a few punctures in the wing and fuselage, but those will be easily repairable. I spent some time repairing it and reattached everything.

It of course is a scratch built stick and tissue model. Right now it is hanging off my right wing next to my DH2 Beaver.

It's on wheels right now, but floats should be easy to fabricate up.

Project Status:
Wings: ~126.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~228h

I spent about two hours on misc items that needed to get done on the wing. The filler cap hole template was made, but not without complications. I'm not sure how Zenith expects you to back drill into the scrap. If the tank is in place ( which it must be in other to align the template ) then you can not possibly fit a drill between the tank and the spar to drill into the template. Also, fitting a drill from a rib would be another feat.

Instead I used a sharpie to mark a hole in the template from the rib, drilled that, then used a sharpie to mark the hole from the rib, then precision drilled that hole.

The strobe wire was cut, and I expanded the two tank rib tooling holes to fit the wire. The rest of the wire is in PVC. My thought was if I could further expand the tooling holes to fit the PVC and therefore be able to feed the wire all the way down the wing. The two concerns I have are 1) would expanding that hole cause need for additional reinforcement? 2) would the required bending put strange stresses on the wing?

Project Status:
Wings: ~124.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~226h

I corked the left tank along with the tank channels and then spent time figuring out the path of insertion.

With the channels in place the fuel tank will not fit. Instead have the inboard channels clecoed, insert the fuel tank and then slip the outboard channels between the rib and tank via the lightening holes.

I measured as best as I could for the placement of the fuel drain and fuel supply holes, but missed a bit. The hole in the rib was closest and was only enlarged a tiny bit. I may consider adding some scrap aluminum to the fuel drain hole just to make it look better.

Project Status:
Wings: ~122.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5 )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~224

It took about an hour to get the fuel tank channels drilled into place on the left wing.

The approach I took was simple: predrill the ribs then match up the channels on the flange. The top hole on each channel was drilled on the workbench first and then clecoed to the matching hole on the rib. This made clamping easier.

The determine where the holes went on the rib I eyeball centered the channel marking the top and bottom edges, and then measured the edge distance as the top and bottom holes. The remaining holes were set evenly by eyeball measurement.

Project Status:
Wings: ~121h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~222.5

Most of the night was spent talking to neighbors about the project, and an hour was spent building.

The tank channels were cut to size and an A4 hole finder was fabricated.

I also stopped by a NAPA and acquired some wiring supplies for the fuel tank.

The hole finder was simple to make using some scrap from the slat hole skin supports that I made in the incorrect direction. I kept some of the flange to provide stiffness. At first I had the rivet head centering the tool, but that didn't work too well on A3 holes. Flipping the rivet so a partially pulled rivet's bulb does the centering worked much better.


Project Status:
Wings: ~120h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~221.5

It was a two hour battle to get the fuel sender into the tank, but I won.

Luckily there was a Tacoma Screw literally right on the other side of the highway from my office, and they carried unibits and a fly cutter that fit my drill.

First, unibits are expensive.

The night started with me testing the new fly cutter on some scrap metal. I clamped the metal to some beams to simulate the flexibility that the fuel tank would have. Then I made a pilot A4 hole. With the circle cutter, I found that the metal flexed ( predictable ) and caused the cutter to hit unevenly and snag. Luckily snagging did not cause any tears or dings.

The solution was to use the drill to score the metal and then hand rotate the cutter until the hole was made.

Next came the tedious process of deburring and slowly enlarging the hole from about 57mm to 59mm. I spent almost an hour on this alone so as to work slowly and not accidentally oversize the hole.

Finally the sender slipped in and I was able to tighten the screws. Unfortunately I had the unit upside down as I found out when I used the Ohm meter to test it.

Project Status:
Wings: ~119h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~220.5

Sunday was spent preparing for the fuel tanks. A few rivets on the bottom wing skin still had to be pulled by hand as well.

The manual is slightly confusing in it's instructions for bending the fuel floats, and I couldn't find the schematics anywhere in the plans. In the end it was best just to look at the photos for clarification. I'm not sure if my skills with pliers need work, or if I'm weak, but it really took strength to make the required bends.

I practiced with the circle cutter and found two major problems: 1) None of my drills can take the shaft 2) Hand rotating it only causes the metal to rip.

Therefore I need to figure out a better way to cut the circle OR I need to buy a drill press.

Project Status:
Wings: ~117h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~218.5

Arlington 2007 ( Saturday )



Edit: Since the first posting of these photos, I became unhappy with the color balance of a few of these "prints". Since then many of these have been readjusted to my liking.

If you want any of these photos in a size larger than 1600x1200, just drop me a line.

On Saturday was spent about two hours deburring, chromating, and riveting the bottom skins and spars together.

A new hand riveter had just arrived from Zenith which made the flaperon brackets much easier.

On Sunday we had a nice day at Friday Harbor.




Project Status:
Wings: ~114h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~215.5

Tuesday night we spent about an hour finishing the drilling into the spar on both sides. The bottom is drilled out to A4, and is partially deburred. Wednesday we should finish the deburring, corrosion protecting, and get the bottom skins riveted on.

My inspection plates arrived today, so I may install those as well.

Project Status:
Wings: ~112h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~213.5

Monday night I got the nose skin drilled on the wing. I also finished the pilot holes from the nose skin into the top part of the spar.

The kit that Zenith provides has the front edge of the top skin predrilled, but not the nose skin. This is a problem since the nose skin overlaps on top of the top skin. The get around this before placing the nose skin, the top skin had several holes drilled into it into the spar which were marked with a sharpie on the skin.

When the nose skin was ratcheted on, I slipped it underneath the top skin and drilled those few holes using the lowest speed of my drill so I could find the matching spar hole beneath it.

Once those holes were clecoed, I then drilled lightly through the skin, trying not to enter the spar.

Once all the holes were matched, I slipped the nose skin over top the top skin, clecoed through the skin into the few holes that were in the spar, and then drilled through the remaining matched holes into the spar.

To help move the nose ribs into place, I made a hook out of some PVC that was laying around.

A few days ago I ordered my fuselage kit along with the bubble door option. I also ordered Jon "Crash" Croke's fuselage construction DVDs. I'll have a review up in the next week or so.

Also on it way are inspection plates and my lighting system. I decided on going with a ready solution since I would still have to match a driver unit and get the lenses.

Here is the Wick's page on the GS LED unit I will use: http://www.wicksaircraft.com/catalog/product_cat.php/subid=7000/index.html

Project Status:
Wings: ~111h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~212.5

There was no working on the "Sky Jeep" over the weekend. Instead, the real Jeep was taken out and given a proper workout.

Picasa has now added the ability to not automatically start the embedded slide shows. Please hit play or forward to navigate.

It took about two hours to get the skins back on, clecoed into place, get the nose skin on and drill the bottom of the nose ribs.

On this wing the bottom spar has not been drilled yet, spare about a dozen holes ( A3 ) to keep everything from beer canning.

This will add the extra steps of having to take the skins off again... and put them back on again before riveting, but should make for a better fit.

Project Status:
Wings: ~109h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~210.5

Look Mom, no clecos! We spent about three hours on Sunday finishing some deburring, corrosion protecting, and riveting.

About mid afternoon, about 15 minutes after hauling the bottom wing skins, spar, and a few other pieces out... and spraying them... the skies opened up with a freak rain storm. All the pieces were quickly taken back into the garage and dried off.

A good bit of time was spent using the lessons learned from the other wing and attempting to get the rivet order correct. The brackets on the fuel tank channel and rear channels were done first, followed by the flaperon brackets to the ribs, followed by the ribs into the spar.

The rear channel needs to be done in a specific order: work from inboard to out board leaving the outboard side of the channel being riveted unclecoed so the channel can be pushed for clearance of the gun head. Since it is easily accessible, the root rib should be riveted last to the wing channel.

Project Status:
Wings: ~107h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~208.5

No building Wednesday night, just flying.

Thursday is the solstice, so I wanted to take advantage of the beautiful lighting conditions that occur in the northwest.

EAA 1440 met tonight with a talk by Precision Airmotive. Honestly it was more info about carbs and fuel injection that I hopefully will ever need to know.

Due to the meeting, I only spent about an hour actually working on the plane. All wing parts ( except for the spar and skins ) were corrosion protected. The rest of the time was spent watching paint dry.

All the wing ribs, brackets and channels amazingly fit into a produce delivery box.

Project Status:
Wings: ~104h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~205.5

We spent another two hours deburring. The skins still need attention, and everything still needs Zinc Chromate.

Project Status:
Wings: ~103h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~204.5

We spent about three hours finding more holes that needed to be enlarged to A5 or A4 while starting the deburring and disassembly of the left wing.

There was a light drizzle today so none of the parts were corrosion protected.

The garage needs to be rearranged so the left wing can be hung as well, so the shelves will have to be moved with perhaps some more storage.

Project Status:
Wings: ~101h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~124.5 hours

We spent two hours on the project and made great progress. The jury strut supports are now in and all of the skeleton has been drilled to the proper hole size. The skeleton is now ready for deburring and can be riveted along with the bottom skin.

We also crossed over the 200 hour mark of the project.

Project Status:
Wings: ~98h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~202.5 hours

We spent an hour first cutting the the 8 pieces of L angle, then positioning the flaperon arms with the template, then verifying the position of the arms with string..... then drilling the arms into place.

With this wing the flaperon arms were more forward on the brackets, so I drilled an additional hole into the arms to compensate for the holes I did not feel to have adequate edge distance.


Project Status:
Wings: ~96h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~199.5 hours

It took about two hours to get the strut angle in place and drilled. The strut attach point is also now pilot drilled to the support. Most of the time was spent waiting for the compressor since the right angle attachment wastes a large amount of energy and drilling out various holes to A4 so A3 clecos could be reclaimed.

I think I have my lights picked out. A set of LEDs offered by Wicks. LED lighting is one of those "must haves" given the limited output of the Rotax alternator and the expected draw from the Dynon and radios.

Project Status:
Wings: ~95h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~198.5 hours

We were camping all weekend, so Friday night was all we got in until today ( Monday ). Two hours were spent getting the bottom edge of the front nose skin in. I had only drilled a few holes in the spar from the bottom skin, so it was easy to get the entire skin lined up. The strut support hole had to be enlarged on the inboard side exactly like on the other wing, but this time I bolted on the strut attachment with the skin off, saving time and frustration.

The strut angle is marked and ready to be drilled. The only issue is that we are running low on silver clecos ( AGAIN!?!?!?!? ), so more A3s had to be enlarged to A4s. This helped eliminate some of the ( very limited ) beer canning anyway.

And now for some purty pictures:



Project Status:
Wings: ~93h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~196.5 hours

I finally found some energy to get back into the garage. It took about two hours to get the rear bottom skins drilled into place. The biggest time sinks were having to cleco myself and reclaiming silver clecos. It is hard to imagine that we are low on A3 clecos again, but we are. To get clecos back I drilled some holes out to A4s.

When you are placing your holes for the outboard side of the flaperon brackets the manual states that the hole is 10mm from the bracket, but there is a better way of finding the hole. Simply extend your rivet line from the ribs down to the rear channel. Drill where the two lines intersect.


Project Status:
Wings: ~91h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~194.5 hours

I spent about two hours on Sunday getting the trailing edge skins ready on the right wing. They are all ready to be drilled.

This week will be light on the building. More to follow.

Project Status:
Wings: ~89h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~192.5 hours

It took me an hour on Thursday to cleco the left wing skeleton back into one piece. Then I went flying for a couple of hours...

Friday we spent about four hours getting both the top and bottom skins into place and drilled. I learned my lesson this time and only drilled a few holes into the spar on the top skin. The bottom skin also only has a few holes drilled into the spar, although it did not cause any problems last time.

The left wing went much faster and we had a much easier time getting the flange lines into place.

Thursday I did another cross country in a Super Cub, this time to Whatcom lake and Lake Cavanaugh near the Canadian border.



Project Status:
Wings: ~87h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~190.5 hours

I once again spent my afternoon in a Super Cub... with an 84" prop.

We had lunch at Lake Wynooche in the Olympic Mountains while talking shop in a way that satisfied my BFR.

Is there a better way of spending the day?



In project news I have the nose skin now in place. Only a few of the holes for the slat support and the spar extension need to be placed.

Those fuel tanks are just around the corner!

I spent about an hour Tuesday morning struggling with the nose skin, only succeeding in giving it more "smilies". I ended up calling Zenith and realized that I needed to use a loop strap that wrapped around the wing.

Later in the afternoon I made a trip to Home Depot for new straps. I placed some wood up against the flaperon brackets to protect the trailing edge and everything worked well. I slipped the nose skin underneath the top skin and have had good success with the existing spar holes. I am simply using low speed on the drill and stopping as soon as I feel the nose skin being penetrated. I then inserted a cleco and searched for the existing spar hole.

My after noon was spent with a Cub Crafters Top Cub on the Snohomish River. Today I have a couple of hours and am going to take care of that pesky BFR.




Step Taxi near the 522 bridge





Taking off





Project Status:
Wings: ~82h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~185.5 hours

Some photos from Paine Field's General Aviation day that was held on Saturday the 19th.

It took one hour to get the jury strut attachment ( 7v10-4SP ) points into place. The plans were a little hard to read, and the presence of predrilled holes further exacerbated the issue. A partial solution for both the front and rear was to drill the middle hole and then cleco it onto the wing. The foreward support then needed to be removed, the nose rib moved into place and then drilled to the skin in two places. Then the cleco that should hold the jury strut had to be removed, the jury strut attachment replaced and then back drilled into from the rib side.

It took four hours to rivet the remaining skeleton and bottom skin. A few A4s were accidentally put where A5s should go, so I had to drill those out.

Currently the nose skin is clecoed to the skeleton. Strapping the nose skin is always the hardest part. To complicate matters I already drilled through the pre-drilled top skin into the rib. To work around this I will drill the skin to the nose ribs first THEN slip the nose skin under the top skin, then mark where a few holes are supposed to go. I will then slip out the skin, drill those few marked holes with an A4 bit, slip the skin back under and cleco the top skin back onto the spar through those holes. Once that is done all the holes on the top skin should align with the existing holes in the spar and the nose skin can be pilot drilled. Once the nose skin is pilot drilled, I will then slip the skin out and place the nose skin over top the top skin. To help I used the edge distance tool to mark where the nose skin should reach.

Project Status:
Wings: ~80h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~183.5 hours

I did my first building since our vacation and recovering from the food poisoning associated with said vacation...

It took three hours to put the wing skeleton back together and rivet the rear channel and the fuel tank channel.

Part of the time was spent drilling out rivets due to some thoughtlessness on the rivet order. Here is what I learned:

• Rivet the rear channel and their angles first.
• Rivet the (L) angle to the fuel tank channel second.
• Rivet the Fuel tank channel to the ribs before riveting the rear wing channels to the ribs. This allows easier access on the inboard side with a pneumatic gun.
• Rivet the flaperon support brackets before riveting the wing channels.
• With the wing right side up, rivet the rear channel to the ribs from the outboard working your way inboard. Have the inboard piece of the channel you are riveting disconnected so you can push the nose of the gun inside. Use a hand riveter with a swivel head to get the heavy channel that has the strut support.
• Have someone else help you so you don't have to put down the rivet gun!
  

Project Status:
Wings: ~75h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~178.5 hours

Seven hours of deburring, disassembly and chromating. The wing is still in pieces. Lets hope I can put it back together again when I return from vacation.

In other news I splurged and flew a Cirrus for the first time. One point seven in an SR-20.

Project Status:
Wings: ~72h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~175.5 hours

We spent two hours Friday morning fabricating the flaperon supports and then drilling them into place. An easy job, but it takes a large amount of un-clecoing and re-clecoing. You also have to be careful about protecting the skin.

Saturday night we spent about 3 hours. I went back and drilled out all the A3 holes on the skeleton to A4s and A5s. There are still a few places that need to be enlarged but the skin must be removed to reach those ( all on the rear channel ).

It took a long time to change to color of the skin clecos. Only the bottom skin was drilled out, but it was a long process. We also cleaned the garage out.

Project Status:
Wings: ~65h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~168.5 hours

Saturday had about 3 hours of building, and Sunday had about 4 hours.

On Saturday we got the forward strut attach point bolted along with all the other related pieces drilled into place. Tightening the bolt closest to the skin is a major pain. Maybe some sort of inspection port nearby would be a benefit.

Sunday I fabricated the flaperon positioning template and got the flaperon arms into place. I found a good way to check if the holes are co-linear. Just use a spool of thread. Have one person hold the thread tight on one end, and then hold it tight on the other. If the holes are not co-linear then the thread will indicate which way the bracket needs to be moved.


I bought a right angle adapter from Home Depot a while ago, and it came in handy. The builders manual shows a nice way of not damaging the skin when using the drill in tight spots... a nice tip to have had earlier. My variation used an extra piece of heavy wing channel that had to be trimmed off. Since the wing channel is bent on both sides, the chuck can not move the protecting piece out of the way.

There is an optional step to place the tie down rings. I do not remember receiving the tie down brackets, although I could fabricate my own. The position of the brackets confuses me. It seems that attaching the bracket to the fifth rib is not the strongest place. Why is the loop not attached to the strut support? The strut support already is attached to the spar which would be a better place in case of a wind storm around here.



Project Status:
Wings: 60h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~163.5 hours

On Sunday we 1) Finished trimming the rear wing skins 2) Drilled them into place 3) Got the nose skin clecoed into place and confirmed the slat support slots were in the correct position.

The manual shows how to cut the flaperon hinge slots into the rear skins with a drill. I tried to do that for a few holes and ended up wandering with the bit too much. A much better approach is to use a reinforced cutting blade on a Dremel.

Thursday we got a package of 200 silver clecos from Wicks... which is possibly too many clecos.

I freshened up on my float skills today with splash downs in Lake Washington and the Snohomish river. Drivers on the 522 bridge got a show as we approached down into the river and passed overhead by less than 50 feet. Then some fishermen got a show as we flew along the river about 10 feet off the deck making tight turns to follow the river bed. I could make out details on one of their faces....

Project Status:
Wings: 53h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~156.5 hours

Monday I got a little time in to start trimming and placing the rear right trailing edge wing skins. While the plans normally show the right side of an object, the skins are sometimes shown as they appear on the left side. Take note and be careful.

EAA is tonight, so probably no building will happen. I expect Wednesday, Thursday and Friday to be a full on spree!

Project Status:
Wings: 53h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~153.5 hours

Another 200 silver clecos are on their way.

We found some time over the week and on Sunday to align the spar and support the trailing edge in such a way to ensure no twist. The bottom skin was pre-drilled and fit over the skeleton fairly well. Since there is a bit of a curvature to the bottom of the wing ribs we ended up using some duct tape to help hold the skin towards the trailing edge to help keep the skin from beer canning. Over all this was the easiest skin to apply yet.

Project Status:
Wings: 52h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~152.5 hours

We did not build on Sunday, but rather took a nice long file up to the tulip fields.

The weather was threatening on Saturday so we drove to Wick's. The traffic was horrible and conditions only improved.

In the end they only had 70 silver clecos, but anything helps.

Wednesday night we spent about half an hour securing the spar and ribs to the table.

We ended up having to remove several of the small shims securing the ribs since they interfered with moving the skeleton to match the pre-drilled holes on the skin. Using several rafter squares clamped to the rib and spar worked wonderfully.

Thursday saw a good two hours of drilling the top, rear starboard wing skin into it's respective skeleton. This would not have been possible without the generous lending of clecos to me.

The electric drill did a much better job of drilling into the spar, while the air drill was faster drilling into the ribs.

Hopefully I can get up to Wicks on Saturday and buy another two hundred clecos or so. I'm also low on zinc chromate.

I also got to see one of the many RV-7 projects our chapter has. Van's is really onto something with matched-pair drilling. If the RV-12 kit has the same amount of pre-drilling on the skins AND the ribs, then the 601 will have some real competition in the LSA area.

Project Status:
Wings: 49h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~149.5 hours