Tuesday, December 20, 2011

More right wing, nose skin

Things are moving along.  It's really starting to look like a wing now.

Another view:


A 12' wing nose skin with bend in it is pretty wobbly to maneuver in a tight space.  It just takes a lot of patience to check the wing spar angle, and the level of the main spar and the rear spar.  Lots of drilling, and my hands are getting strong using the cleco pliers.  Took a while to set up the straps and slide the nose skin under the rear top skin for drilling.

This is a picture taken inside the wing.

And below is the aileron bellcrank mount, seen through the access hole.


BTW the loose L angle is something I was using to position the ribs under the pre-drilled holes in the skins.

Sunday, December 11, 2011

Top Rear Skin, Right Wing

It's starting to look like a wing.  I almost didn't want to start drilling it, because the smooth skins are so pretty.  Just like the directions say, if I tilt the main spar 9 degrees and level it, the rear spar should be level as well.  I took some time to make sure these were both true, then I positioned the skin to line up the rib flange centerlines  with the holes in the skin.  I held it in place with duct tape.


I started drilling and clecoing from the middle of the rear and worked my way out towards the sides.  I used clamps and duct tape to make sure the aft edge of the skin was flush with the back of the rear spar upper channel.
It's a great feeling when the black line shows through the pre-drilled holes - it makes me feel confident I have the wing lined up with the proper twist.  Then I took the obligatory picture through the lightening holes:

My son helped me flip it over, and the I set the 9 degree angle and leveled the main and rear spars.  Next comes the L angles reinforcing the top skin, and the bottom rear skin.

Saturday, December 3, 2011

Right Wing Skeleton

Okay, it's been a while since I've posted.  Work has progressed to the wings.  I finished the flaps and the ailerons, and now I"m working on the wing skeleton.


I'm working in the garage in December in Minnesota, so it gets a little chilly and I have to keep the place heated.
The ribs come pre-formed in the kit, and that is nice.  The main spar (on the right) is fully pre-formed, and corresponds to the new "B" series reinforcements.  It's so pretty I didn't want to drill any holes in it.  Also, things get pretty tight in the corners, especially where the nose ribs are attached.  I decided to go with a McMaster Carr right angle drill attachment on my Sioux air drill to get in there.  Lots of clamping, cutting, and fitting of the nose ribs, along with some careful additional joggling of the ribs to get them to fit.  The rear ribs come pre-joggled, but I think it's for the earlier main spar.  They didn't quite fit, and I used the dimpling tool to increase the joggle.  I considered cutting off the corners of the ribs; That's what Zenith recommended on their upgrade videos.  But I figured leaving the metal has to make it a little stronger.