Gluing the lower right wing, wing walk ply

February 28, 2011

Tonight I cleaned off the excess glue from the leading edge gluing and made one last fit and cut of the wing walk ply. I then transferred over to the upper surface of the I-strut area. I marked the aft edge where the aileron cove area ply will meet up with the I-strut ply and then trimmed the I-strut ply to match. I decided not to glue the i-strut ply as I wanted to glue the bottom first so that I would be able to mark the sweeping location for the bell crank. I then went back to the wing walk ply and glued that into place. I used the left over glue to glue the upper wing right side lower aileron cove strip.

Time spent today 2.5 hours
Total time spent 545.5 hours

Taking off the right lower wing leading edge clamps

February 26, 2011

Today I didn’t have much time but I did make it to the basement to work on a few things. I removed the clamps from the previous nights gluing session. I cleaned up the joints a bit and removed it from the jigs. After that I worked on the upper wing hand hold area and tapered it to the correct taper using some 60 grit sand paper and my jitterbug sander. I fine tuned some areas with my file but that seemed to come out good. I then measured and cut the ply that goes in that area using pieces I had already cut from the top side as templates. After that I went over to the lower left wing and examined the pitot static probe re-inforcement all seem well and I widened the hole to allow the probe. I also widended the leading edge hole as well. Again I forgot to take pictures. I will post some later. I think I am about ready to glue on the lower left leading edge but I will leave tha to another day.

Time spent 2 hours
Total time spend 543 hours

Gluing the lower right wing leading edge

February 25, 2011

Tonight my wife graciously suggested that after work we should get the lower right wing leading edge glued and installed. You just got to love her she is as anxious to get these done as I am. We basically did the same thing as we didn on the upper wing leading edges except I only mixed up 3 oz of T-88, which was not enough I think 3.5 oz would be perfect. It was suggested to me to slightly microwave the T-88 to get it runnier to make it easier to spread on the leading edge but I didn’t think it was that necessary so I just went ahead and did what worked before. After that I worked on the lower left wing pitot static area to add a support just incase someone bumps my Pitot static probe. All I did was glue some left over 1/4 by 1″ and 1/4 by 1.5″ spruce I had left over together and then glue that between the two nose ribs in the pitot static probe area. After that dries i will shape it to the nose rib shape and drill a hole into the center of it. This piece will beef up the leading edge area as it will be supported by the two ribs that will be glued to the leading edge and it will glue to the leading edge.

Time spent tonight 1.5 hours
Total time spent 541 hours

Moving the Upper wing off the table and starting the lower wing leading edges

February 24, 2011

Tonight i decided to drill the flying wire acces hole into the I-strut bay sheet I also did some general sanding of the recently glued joints. I moved the upper wing over the boxes and the lower wing back on the work table and re-jigged them for no twist. I did a bit of sanding to get the drips from sealing the front spar with system three clear coat and a general cleaning of the ribs in preparation for the lower right wing leading edge. I then measured and drilled the flying wire holes and acces holes in the leading edge IAW demensions of the S-1S drawings. I then installed all the I-strut lugs cotter pins and bolt in the crush plates. It was getting late so I decided to call it a night I will glue the leading edge on tomorrow night. I did some shaping of the lower hand hold area just before I turned the lights out but it will need somemore tomorrow.

Time spent today 3.5 hours
Total time spent 539.5 hours

Upper wing top side I-strut bay sheeting

February 23, 2011

Tonight I removed the clamps from the previous days gluing of the upper wing right side leading edge. I sanded some of excess glue that squeezed out of the joints and drilled out the front spar I-strut bolt holes. The leading edges looked great.

I then measured cut and fit the I-strut ply sheet to the proper angle, I also trimmed to match the ribs. I haven’t glued the aileron bay sheeting yet but I clamped it in place for measuring and then removed them. I then mixed up a batch of glue and glued the sheet down.

Time spent today 2 hours
Total time spent 536 hours

Installing the upper right wing leading edge

February 22, 2011

Tonight was very similar to last night in regards to installing the leading edge. I started by installing the flying wire lugs and crush plate. I then filed the ribs slightly to get any clear coat off and to rough up the surface. I checked the fit of the leading edge one last time and positioned my clamps and ratchet straps. Finally I double checked that the wing had no twist. My loving wife (she’s a trooper T-88 is sticky and she never complained) came down to help me again but this time I mixed up 4 oz mixed of T-88 (2oz part A and 2 oz part B). My method this time to was spread the glue along inside the tip of the “V” of the leading edge with a mixing stick and once I got good coverage using a plastic putty knife to pull it up the sides. I had some left over glue this time so my best guess the upper leading edge requires about 3-3.5 oz of epoxy but having left over is better in my mind. I applied the glue to the ribs and filler strips and installed the leading edge just like yesterday using straps clamps and staple strips. After that I did a little sanding on the joints for the center section and the left leading edge I also located and drilled out the I-strut bolt holes on the left side.

Time spent today 2 hours
Total time spent 534 hours

Gluing the upper left leading edge and riveting the nut plates

February 21, 2011

I started the day off by taking the aileron hinge backing plates to the airport to rivet them. I got to the airport and first thing was to counter sink the back side for the rivet. I also enlarged the holes to 17/64″ to give more room for a not so tight fit. I went ahead and squeezed the 3/32″ rivets into the nut plates. After I got home I primed and painted them. Now they are just waiting to be installed.

After that I installed the upper left wing flying wire lug. When I installed it some of the paint scratched off and I painted it back on. I installed the outer rings and cotter pinned them. I did a last minute check on the drag wire nuts to make sure they were tight and locked. I also made sure the wing had no twist. I waited for my wife to get done painting the guest bedroom and then asked her nicely to come and help me since you need at least two people to install the leading edges. I started by laying out all clamps, ratchet straps and wood. I used yard sticks from Lowes for my staple strips. I covered the yards sticks with packing tape to make them “un-stick-able” with the glue in the vicinity. I had read that the Pitts Model 12 leading edges take about 2 mixed oz. of T-88 to cover the inside of the leading edge as well as the filler strips and ribs. I spread glue on the bottom side first and then on the top side. Meanwhile my wife spread the majority of the T-88 inside the leading edge using a cheap (84 cent) plastic putty knife. T-88 is really sticky and it makes it hard to spread on the leading edge. I ended up needing a bit more T-88 so i mixed up a separate batch to help finish the job. My guess it that the 3 total oz of T-88 is required per leading edge to just make it easier. Anyway we got everything covered and then installed the leading edge. I pulled everything snug with the ratchet straps and I clamped the back end and stapled everything in place. I didn’t staple the I-strut area and used a clamp instead.

After that I mixed up a batch of clear coat to pre-coat the aileron ply plates on the spars. I also took the opportunity to to a second coat on the lower wing forward spars in preparation to install those leading edges.

Time spent today 5 hours
Total time spent 532 hours

Upper wing center section ply, aileron hinge nut plates and other things

February 20, 2011

Today I decided to get right to work and glue the center section upper surface ply sheet. I started by cleaning the joint of all left over glue to make the joint as clean as possible. I glued the ply down and then using the pieces of wood covered in tape that I used to glue the leading edge with I stapled them in place center first working my way out. I did the front and aft surfaces making sure they stayed aligned with my center-line marks.

After that was done I worked the the upper wing leading edges to drill holes for flying wire access. I marked out the hole centers using my S-1S plans locations they looked about right so I drilled a pilot hole and when that was good I widened the hole to 1-1/8″ like the drawings say and they work perfectly. You can see them in the picture below.

After that I primed and painted all four of the flying wire lugs in preparation for final installation. I last minute decided to prime and paint them. I initially didn’t want to do this because of the already tight fit. But, I figured I would try it anyhow and any paint that gets scratched off during install I will paint back on the other side.

Finally I finished installing all the grommets and checked out out the pitot static lines fit. I of course marked the P for Pitot and S for static for future reference.

I also cut all my aileron hinge backing plates drilling them for nut plates and the holding screws. Tomorrow I will rivet the nut plates to them and paint them.

Time spent today 7 hours
Total time spent 527 hours

Lower left wing pitot static lines

February 19, 2011

Today I removed the clamps and stapled on sticks on the center section leading edge. The glue job came out well. I had to do a little bit of edge filing to make the joints square because of the squeezed out glue but it was pretty easy. I then removed the clamps on the lower left wing pitot static tube holders. I drilled two 3/8″ holes vertically in each holder and inserted rubber grommets. I temp routed the pitot static lines to check the fit. Now I need to head to the airport to flare the ends of the tube so they will seal.

I had some filler sticks that have yet to be glued on so I mixed up a small batch of glue to glue those on. I used some left over glue to glue the final pitot static tube holder.

Time spent today 2.0 hours
Total time spent 520 hours

Gluing the center section leading edge

February 18, 2011

Tonight I thought it was high time to try out gluing a leading edge. I started by mixing up a batch of T-88 enough t cover the center section ribs and filler strip. Right after that I mixed up batch of clear coat to coat the inside of the leading edge. Since the two epoxies are compatible you can glue them a the same time. I then spread the clear coat on the inside of the leading edge making sure to get a nice coat on everything. I then let that sit and spread T-88 on the filler strips and the on the ribs making sure to work neatly as I will need nice joints for the other leading edges and cover plys. I installed the leading edge and then pulled it tight with my ratchet straps and some plastic covered wood to draw the skin tight. I finished off with some packing tape covered 1/4″ thick wood and I used my industrial stapler to staple that aft end of the leading edge to the fill strip. The 1/4 thick wood will allow my to remove the staples tomorrow.

After that I used the left over clear coat to make a second coat on the front spar front surface and in the lower wing walk area. I also used the left over glue to glue some 1/16 wood to the nose of them left lower wing to support the pitot static lines in which I will drill those out and install rubber grommets.

Time spent today 3 hours
Total time spent 518 hours