Gluing the lower wing aileron cove ply

March 31, 2011

Today I got right to work cutting and trimming the two lower wing upper side cove plys. I did this much the same as I have in the past except I used an abundance of cloths pins to clamp the trailing edge down.

Time spent 3 hours
Total time spent 598.5 hours


Gluing the lower wing upper side I-strut bay ply

March 29, 2011

Tonight I worked on the lower wings upper side I-strut bay plys. I started locating the spot were the 90 deg bell crank bolt on the ply and drilling a hole that allows a socket wrench in and the bolt out so that if I ever want to remove the bell crank I can after cutting a hole in my fabric of course but the option is there. Also I drilled a hole for the control rod bearing bolt so that I can install those and remove them in the future too. If I ever want to make them a inspection panel I can afterwards (even after fabric) by cutting the hole and gluing a doubler plate on the back side. After that I glue the surface down. I also glued the trailing edge ply strips too.

Time spent today 2.0 hours
Total time spent 595.5 hours


Lower wing bottom side wing walk

March 27, 2011

Today I removed the clamps from last nights gluing of the lower left wing ply pieces. I got right to work gluing the lower right and lower left wing walk lower side plys. I also glued the lower left wing compression strut cap plys and glued the hand hold end caps that I made to square up the hand hold.

I filed and sanded the hand hold ply that I glue yesterday so that it tapers smoothly into the hand hold bow. I also filed the lower right and left wing tip cap to transition smoothly into the tip bows.

Time spent 2.5 hours
Total time spent 593.5 hours


Lower wing cove cap ply and upper wing hand hold center ply

March 26, 2011

Thursday I removed the clamps on the upper handhold left side ply and the lower left wing aileron cap strip. I then tapered the ply on the upper hand hold into the hand hold bow like you see in the below pictures. Lastly I mixed up some clear coat and coated the areas that would be hard to get to when I glue the aileron cove cap ply.

Friday I fell asleep on the couch watching TV after a long week at work no work on the wings.

Today I trimmed and cut the hand hold center ply. I then marked and cut the hole for the hand hold using a utility knife. After that I cut and trimmed the lower right wing lower side aileron cap and tip ply. After that I glued both the hand hold and aileron cap ply. I also cut the 1/4″ cap plys for the lower right wing and one of the lower left wing and glued those too.

Later that evening (11 hours later) after I did some yard work and watch some movies I went down to see if the glue had set up and it had. I then un-clamped everything and mixed up some glue for the lower left wing aileron cove ply. I also cut and glued the lower right wing compression rib ply and the lower left wing 1/4″ rib cap plys.

Time spent today and yesterday 4.5 hours
Total time spent 591 hours


Gluing the lower left wing lower aileron cove strip and the upper wing hand hold ply

March 23, 2011

Tonight I removed the clamps on the lower right wing lower side aileron cove strip clamps. I also removed the clamps on the lower right wing, wing walk ply. I went around to the various areas I had glued the day before on the upper wing and sanded the joints to make them perfect. I then worked on the lower left wing lower side aileron cove strips by cutting some notches to allow the hinges to slide out in the future. I also cut the joint for the tip piece that comes out to the tip bow. I then trimmed and rehearsed the clamping of the hand hold ply. I mixed some glue and glued the hand hold ply and the cove strip in place. After that I cut and trimmed the lower right wing lower root plys.

Time spent today 2.5 hours
Total time spent 586.5 hours


Upper wing compression strip ply and lower right wing aileron cove strips

March 22, 2011

Tonight I got right to work by removing the clamps on the previous days gluing the of the upper wing right side aileron cove cap plys. They came out well and I immediately started to trim the extra wood off the tip bow and sanded it to shape on the both the upper left and right tips. I finished it off with 150 grit sand paper they both turned out as good as their brothers siblings on the lower side.

I then cut and fit the compression rib cap plys those were ready to glue down. I then moved over to the lower right wing aileron cove and cut and trimmed the lower side aileron cove strip. I notched the top and bottom side so that I could remove the hinge in the future, I would be able slide it out. I then mixed up some glue and glued the strip down and the upper wing compression rib plys on the both the upper wing left and right sides and finished by gluing the bottom right wing wing walk ply since it was previously clear coated days before.

Time spent today 3 hours
Total time spent 584 hours


Gluing the upper wing right upper side plys

March 21, 2011

Today I removed all the clamps from the previous day’s gluing session and all came out well. I measured and cut out the backing plate for the lower left wing inspection hole using my utility knife and straight edge. I drilled the screw holes and installed the #8 nut plates with my left over pop rivets. After that I cut and trimmed the upper wing upper right side aileron cove caps. I clear coated the inside of the coves and glued them in place. I had some left over glue so I glued the all the rest of the 1/4″ rib cap plys on both right and left sides. I aso glued the lower left inspection hole backing plate.

Time spent tonight 3 hours
Total time spent 581 hours


Folding the aileron coves gluing the upper wing plys

March 20, 2011

Today I took my newly cut out sheet metal to the airport to put the folds on it. I wanted a 1/16″ radius so I used a shoe of 0.032 that was folded all the way over to make the radius for me. I then put the sheet metal in and made the first fold. So far so good. The second one went just as easy. I took them home and cut the hinge holes out and tried it out. First off the radius dosn’t want to conform easily so I removed the cove and using 3/4″ dowel and clamps I clamped a radius in to the cove. I then refit it again. This time I used screws to hold it in place. The metal start to pucker on the top side a bit and I didn’t like the fit so threw in the towel. In the picture you can see the crease in the center of the cove. The top fold doesn’t look it it fits but it actually does when the cove is pull to shap by the screws.

While I was at the airport I grabed some left over Lexan from a belly skin window and made two inspection windows for the lower wing bell crank inspection hole. I counter sunk the screws and cut out the radius for the arm. I’m really happy with the way this came out.

Later that evening I cut and trimmed the aileron cove cap for the upper wing upper left side. I had to clear coat the inside prior because getting the clear coat in there would have been difficult after the cap was glued on. I also glued the rib cap plys for the

Time Spent Today 6 hours
Total time spent 578 hours


Gluing the last upper wing plys

March 19, 2011

Today I cut and trimmed the upper wing lower side I-strut plys. I also drilled some access holes for the after spar fitting to accommodate the clevis’s and pins. I then put a second coat of the clear coat on the inside of the I-strut bays and glued the I-strut ply in place. I also glued the center section ply.

I received a shipment from aircraft spruce on Thursday and in that shipment was some 2024-T3 0.016 thick aluminum for the aileron coves. I measured and marked the aluminum and cut the first one out. I need to take it to the airport and and fold the edges. I also measured cut and trimmed the lower right wing walk lower plys. And finally I measured and cut out the square access hole on the lower left wing I-strut bay.

Time spent today 5 hours
Total time spent 572 hours


Gluing the lower left wing I-strut ply and various other plys

March 18, 2011

Today I cut and trimmed up the lower left wing lower I-strut ply and I cut and fit the upper wing aileron cove tip piece on the both lower sides. Once everything was ready I glued the access hole doubler, the I-strut ply, the upper wing aileron cove tip pieces and the lower wing lower side trailing edges. After those were all clamped down and I worked on the lower wing aileron hinges by filing them down so that they fit into the cove. I flied about 1/8 out of the cove strip and about 1/16″ off the top and bottoms of the hinges and that allowed them to slide right in with just a tiny bit of interference. I also glued on a small piece of wood on to the drag block just outboard of the I-strut area for the aluminum cove to screw to.

Time spent today 3 hours
Total time spent 567 hours