Wings - Part V

Things are definitely moving along now.

Flap bellcranks are assembled, and in their mounts.  Next step is to build the flap cable pulley that goes behind the aft spar.  At this point, clearances need to be checked to verify the cables will go through the holes on the spars.  I used nylon line for my weed trimmer.

I can't say enough about having both wings going at the same time... It is more than twice as fast from a build perspective.  The first one (in my case) usually involves some learning, or jigging, or swearing... while the 2nd one goes much faster.

Attach angles for the flap brackets.  These are very fiddly to make.  

Finally... reassembly time!  Ribs starting to go back in...

Main ribs 1 and 2 need to be riveted together... I used the C frame for these... makes a nice job and is very quick.

All ribs installed and riveted.  The cap strips under the forward spar are clecoed in place for when the nose skins go on.

Speaking of nose skins...  I made some jigs to hold the skins while riveting.  I clamp these to the bench.  Worked very well - keeps the entire assembly held firmly.  I can also use the cut outs to clamp the piece into place very firmly, but haven't seemed to need this.

Had some issues with the flush riveting... I have done a bit of this in the past, but never this much, and never on a curved surface.  The squeezed rivets (aft most rivet hole top and bottom, and the end ribs can be squeezed - more if you have a longer yoke) were good, but the bucked rivets were slightly proud.  So after tiring of drilling out rivets, I asked from fellow builders for some advice.  

Seems like I was putting too much pressure on the bucking bar, and not enough on the manufacturer head.  This seemed to address the issue.  I am using a small tungsten bar on the interior of the assembly.

I moved the assembly from side to side in the alley between the wings.  Luckily I could do this on my own.  Simply remove all the jigs except one on each end, and move one end at a time.  When the assembly is all 3 nose skins (16' long), it is rather wobbly.

First nose skin in place.... but I missed one rivet... so it will have to come back down once the other side is done.

2nd nose skin in process.  The first one took me 3 partial days.... the 2nd one was 80% completed in about 2 hours.  Probably 3 hours total.  Building both wings at the same time is the way to do it, no doubt.

Once these two nose assemblies are done, they will need to be inspected before I can move forward.  Submitted the paperwork on 12/31/2019.  Happy New Years eve!

Next steps:

1. Finish nose skin / rib assemblies
2. Rivet nose skin / rib assemblies to forward spar
3. Alodyne / prime main skins
4. Fabricate lower flap track angles
5. Cut slots in lower main skins for flap tracks
6. Rivets lower main skins

Wings - Part IV

Lots of progress since the last update.  With racing season over (at least the racing component), finally have some time to get going on the wings.

 Aileron hinges all fit, primed, and riveted...

  

Aileron bellcranks drilled and primed... part I.  After the attach angles are riveted to the bracket, they are then fit on the spar and drilled in place.  Then finally the small attach angles are drilled in place and riveted.

Assembled bellcranks ready to be fit to the spars.

Small attach angles (4 per side) all cut and pilot holes drilled.

I drilled all of these little angles in place to ensure a good fit.  Used a right angle drill and extended bits depending on the challenge.

Aileron hinges and bellcranks all riveted in place.  I thought the hinges would be afternoon job... NOT.

Aileron pulley bracket.  I clamped everything in place and drilled in place.

All the hinges, bellcranks, and pulleys for the ailerons fit, drilled, primed, riveted, etc.

Onto the flap tracks!  Yay!  I copied Ted Setzer who recommends rounding the edges and having the tracks anodized.  This avoids chipping if painted.

Fitting the flap tracks.  I cut a piece of wood the same thickness as the track and wedges it between the brackets to get the right spacing.

Flap bellcranks... initial fit.  So the manual clearly states that the pilot holes here are drilled wrong.  Why have they been drilled wrong all these years is beyond me (apparently its backwards compatibility with the Glastar).  You have to reclock the arms... but how do you keep everything centered?

My solution was to get some washers from the Home Depot Aircraft Store... I trimmed them down slightly to fit inside the arms and spacers (just shy of 1.5" diameter), and inside the crank where the bearings go (just under 1" diameter).  I then wedges the hole washer assembly together and reclocked appropriately.  

Everything alodined... ready for primer.

Assembly...

All riveted together... looks like a mini Millennium Falcon!

Flap tracks back from the anodizer...

Flap pulley brackets... initial drilling and shaping.

Next steps:

1. Finish flap pulley brackets

2. Mount flap tracks

3. Mount Flap bellcranks and verify cable clearances

4. Remount and rivet all the main and cove ribs

5. Rivet the leading edge ribs to the skins

6. Inspection!