Finishing the tapes on the upper wing, Making rudder cable fairleads, Taping the ribs of the left horiz stab

November 19, 2011

Yesterday I got in an order from Aircraft Spruce which had a 1 ft stick of 3/4″ delrin plastic and 6″ Ceconite 102 light for the the aileron coves. I also got some other stuff but they are unimportant to this post. The reason I needed the delrin plastic is that I 4 of my rudder cable fair leads are 3/4″ 0.049 tub rather than the standard 7/8″ 0.049 tube. Well I couldn’t find a parts supplier that has the fair lead so I decided to make my own for the 4 that I needed. I used my drill press and angle grinder similar technique as a lathe and turned out 4 new fair leads. After the fair leads were fabricated I started working on the large tip tapes on the upper wing. I cut out another tip tape for the right side of the upper wing. I went ahead and installed the two tapes and glued them down. They tape alot of heat to get them to conform to the shape but they do. I then cut out a finishing tape for the aileron coves and glued them in. While things were drying I marked out and started tapes for the left horizontal stabilizer.

Time spent today 5 hours
Total time spent 944


Finishing the Elevator trim tab and covering the right elevator

November 18, 2011

Today I got right to work finishing the elevator trim tab which I folded last night. I got everything situated (piano hinge and tab) then I drilled 9 holes and use some cherry blind rivets to secure everything I checked the fit and everything was good so I started in on covering the elevator. I got the elevator completely covered by the nights end.

Time spent today 4.5 hours
Total time spent 939 hours

Making the elevator trim tab

November 17, 2011

Tonight I went to the airport to use the brake to make my trim tab. I got the airport and used a spare sheet of 0.025 2024T3 to make the tab. I marked and cut out the tab and then made the 1/2″ folds followed by the 3/8 diameter tip fold. It didn’t like the 3/8 fold came out so I cut out another tab sheet and tried again. This time I folded the wrong direction and the tab was backwards. So I marked and cut out a third. This time the fold on the 3/8″ diameter matched and came out good so i went home. This took 2.5 hours about 1.5 hours longer than I expected.

Time spent today 2.5 hours
Total time spent 934.5 hours

Installing the rudder cables, torque tube, and starting on the trim tab

November 16, 2011

Tonight I received my torque tube mount bolts, custom rudder cables, and fairleads from aircraft spruce. I got right to work with the installation of the rudder cable to make sure they fit, and they do. I had to pull the aft end of the fuse out of the rotissere so that I could temp install the rudder to check the cables and measure the exit points of the rudder cables for when I do fabric work. I then started working on the torque tube install. I had installed the stick and the control tube within the torque tube already but realized that I had to remove everyting to get the torque into place. So I did all that go the torque tube in place and got everything tighted down. I then hooked up the control tubes from the elevator to the torque tube idler. I have a bit of travel issues on the aileron because the bearings only move 10 degs either direction and I need them to move 20 deg either direction. I think if I offset the bearings I get a full 10 either direction but I need to mess with that. I would just install a HEIM bearing that had 20 deg of mis-alignment but I can’t find one that is 1/4″ bore and 5/16-24 threads in the female side. More work to be done there. I then moved on to the elevator trim tab. The last trim tab was installed using PK screws through a piano hinge I re-drilled for K1000-8 nut plate for a #8 screw. I need to make to the airport to fold the trim tab up for install. I then can cover that elevator since it is ready.

Time spent tonight 3 hours
Total time spent 932 hours

Covering the top side of the left elevator and rib stitching the left horizontal stab.

November 15, 2011

Tonight I imediatly finished covering the top side of the left elevator. While glue was drying I started and stop and eventully finished the rib stitching on the left horizontal stabilzer. Once the elevator glue was dry I did the initial shrink to 250 deg F. I then cranked up the Iron to 300 and then to 350 deg F. While the iron was stabilizing on the new temps I would continue rib stitching.

Time spent 4 hours
Total time spent 929 hours.

Covering the Left elevator and starting the rib stitching on the horiz stabs

November 14, 2011

Tonight I had a softball game so I didn’t get to work on the plane until late. I decided to go ahead and try to cover the left elevator. I basically did the same thing as I did on the horizontal stabs but I was only able to get the lower side covered in 2 hours. While the glue was drying on the parts I marked and pre-punched both the horizontal stabilizers rib stitch holes. I then proceeded to rib stitch one of the stabilizer ribs. Fingers are imediatly sore like before…

Time spent today 2 hours
Total Time spent 925 hours.

Covering the horizontal stabilizers

November 13, 2011

Today I decided to cover the horizontal stabilizers. I started by applying the EKO bond glue to the tubes and letting them dry to tack. I then took some spare fabric (which I have alot of from the upper wing covering) and cut a piece out that ran with the 90 deg the right way (not in a bias). I attached the fabric to the lower side first using my close quarters iron and then I brushed the glue down in the joint. I then trimed the excess off just like the Stewarts videos show. It really is just like the videos show. I let things dry and did the initial shrink to 250 deg. I marked a 1 inch over lap and did the same as before, let dry and shrunk to 250 deg f. I then repeated on the right stabilizer. After both were done I shrunk up to 350 deg F on both. Finally I marked rib stitch lines and called it a night.

Time spent 6 hours
Total time spent 923 hours.