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

Quick project update:

I have a bunch of photos to upload, but my home computer has been overheating, and it is low on the "fix list'.

Recently I got the tank channels into place, drilled and clecoed along with all the prep work to get the right wing ready for the top rear skin.

Project Status:
Wings: 45.5h ( 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 )
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: ~147 hours

Wednesday I spend a few minutes making the jig for the fuel tank channel, and almost an hour cleaning up my workshop.

Monday some jerk broke into my Jeep at about 9:15AM, right before I normally leave for work, and stole my Garmin 496.

Sunday I finally flew a CH-701, albeit only for a little while and from the right seat. It gave me some renewed vigor to finish the project.

Project Status:
Wings: 44h ( 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 )
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: ~145.5 hours

We spent about three hours on the wings today. The skin support for strut hole was fabricated and placed on the right wing. The left wing got the full treatment of the flaperon brackets, strut attachment and skin support being drilled into place.

More visitors came through the garage. This time a couple interested in building, but also on their way to visit a Czech 701 to potentially buy.

Sunday will hopefully bring high ceilings and actual time in the cockpit.


Project Status:
Wings: 43.5h ( 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 )
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: ~145 hours

I spent about two hours measuring 7V4-4, cutting it, drilling the holes for the left and right wing, and then drilling the right piece to the right wing.

Some "L" angle was also cut and drilled that acts as a brace.

It has taken some time for me to realize this, but the drawing for a piece like 7V4-4 will be found on page 7-V-4. I was trying to determine the dimensions of the piece from the drawing of 7V4-4 that was on 7-V-5.

Right now my plan is to work only on the right wing for the moment since space is now at a premium. Once the right wing is finished, it will be hung on the wall and the left wing will be finished.

Project Status:
Wings: 40.5h ( 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 )
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: ~143 hours

Already got a response!

Caleb got back to me with Zenith's uncanny quickness. The problem was me.

... I would suggest removing all the lines you have marked and starting over. Go to page 7-V-4 in your drawings, at the bottom is the part geometry and dimensions. I would start at the smaller end, draw a line at 16mm from the end, this is the line that the bolt hole is on. From the line you just made, mark a line at 115mm. Measuring from the edge that is 90 degrees to the larger end, measure along the second line you made and mark a point at 27mm. Then from the second line you made measure back towards the smaller end 15mm, make a point on the bottom. Draw a straight line between the bottom point and the point you made at 27mm. Now at the top of the part from the second line you made measure back towards the smaller end 41mm, make a point there and connect that point and the point at 27mm. All of the dimensions and part geometries are in your drawings.

I already used these ( better ) directions and the piece looks like that in the manual. Tonight I'll cut it.

Finally some time to work on the project....

We spent about two hours. The first hour and a half was spent figuring out the best way to get the flaperon brackets consistently placed. The end result was using some extrusion clamped to the top of the rib, then using some "L" angle to hold the bracket to the rib. The ends of the brackets were all made flush with the end of the rib.

I'm not sure how I got into this position in the first place. I drew out the rivet lines on the spar and channel, and the pre-drilled holes of the skin line up perfectly.

But as always, progress must be stopped. I believe that the 7V7-4 supplied with my wing kit may be mal-formed.

Basically making a mark 41mm from the 115mm mark to the right is past the piece. Making the 41mm mark to the left doesn't look right

The instructions in the manual are somewhat confusing, so I would be happy to find out I mis-interpreted them.


Project Status:
Wings: 38.5h ( 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 )
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 )
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Total Done: ~141 hours