Sunday, July 15, 2018

Magnetometer, Aileron cables, Trim planning

We had a little bit of a snafu with the mount we built for the magnetometer.  When we went to install it in the right wing, we found that we didn't have enough adjustment available to get it level within 3 degrees (per instructions for the magnetometer).  We were close, but no cigar.  One side of the magnetometer bracket was just a little short.  Unfortunately, it's harder to add aluminum than remove it.  To fix this, we cut off one side of the mount, and riveted on another piece that was a little longer and allowed us to get put the magnetometer in the right position.  We also found that we can't install the mount quite yet because we needed some aluminum rivets that were a little longer.  Those are now on order and should arrive in a couple days.
Magnetometer mount with new L-bracket riveted on
We also ran the cables for the ailerons and flaps in the right wing (we had already done this in the left wing).  Next, we planned out how we we are going to run the wires for the trim servo within the elevator.  Michael is also experimenting (with his 3d printer), with fabrication of a plastic fairing for the trim servo.

Hours 4.0

Wednesday, July 11, 2018

Header Tank Vent and Wiring Work

We are adding a vent for the header tank in the right main fuel tank.  This will require us to drill a hole in the tank at the high point of the tank and install a fuel fitting/bung.  In order to provide room for this addition, a small section of the root rib was trimmed back with a Dremel sanding wheel.  

The wiring for the ELT and Trim Servo were neatly routed and cable tied from the rear of the fuselage to the front.  High temperature (280F) industrial cables ties were used.  Also, self-sealing silicone tape was added at each attach point to keep the cable ties from abrading the metal members.

All the cable ties around the ELT were replaced with with the Hi-Temp cable ties.  And finally the ELT mounting tray was riveted to the fuselage with CCP-42 rivets.  

Also, the excess material on the mounting tabs of the header tanks was trimmed off.  Hours: 2

Saturday, July 7, 2018

Lots of Miscellaneous Work

Lots of small tasks needing to get done.  The cable connecting the ELT to the "yet to be determined" GPS source needed a connector on the ELT end of the cable installed.  The ELT manual calls for a 3 wire shielded cable from Aircraft Spruce.  The connector was supplied with the ACK ELT and it was soldered on. The ELT instructions call for adding RTV sealant in the connector to keep water out.  The cable was temporarily installed.  New industrial grade high temperature cable ties were ordered for the final installation.  To stabilize the connector at the ELT, a WDG-09 P-clamp was installed.  Also in the same area, two small #30 holes were drilled for a cable tie to secure the coax cable.
GPS cable installed and Coax Cable Secured

The rear windshield bracket was primed and painted a few days ago.  Now that the paint has fully cured, it was cleco'd in place.
Rear windshield bracket primed, painted and Cleco's in Place

Finally, there are areas on the root ribs and butt ribs that needed a coating of the Superflite epoxy varnish.  The epoxy varnish was mixed with the catalyst and reducer in a 1:1:1 ratio.  Hours: 3

Friday, July 6, 2018

Left Wing Cuff Filler and ELT

We've been working on the left leading edge wing cuff and ELT for quite a few days.

On the leading edge wing cuff, we've been adding lightweight epoxy filler to smooth the transition between the cuff and the front spar tube.  Due to the high heat, the filler is curing quite fast, so we are having to work in small batches or we waste a lot of filler.  Then, once we let it cure, it is sanded smooth.  There were also some areas we had left without filler until the cuff was installed.  these areas were the transition between the ribs and the front spar.  Filler was added in these areas as well.
Filler Work Finally Completed
 The ELT plate had been installed quite a while ago.  We finally ordered an ACK 406 MHz ELT (model E-04)  and started the install.  There aren't many options in the ELT installation location.  Using the real parts, the base unit and antenna holes were located and drilled.  After installing the antenna and base unit on the ELT plate, we noticed that there was not enough room to connect a BNC cable to the antenna and not have it interfere with the bottom fabric.  So with a little head scratching and a lot of "what ifs", Ed and I came to the conclusion that a new ELT plate needed to be fabricated with a slight modification in the antenna mounting area.

It was no surprise, but we had to order the correct aluminum plate (0.040" thick) from Aircraft Spruce.  We also had to order the wiring needed to complete the ELT installation, as well as the mounting screws and nuts.

Once the plate arrived, a few days later, a new plate with modification was fabricated and the new bend was made on the metal brake. The old plate was used to locate the mounting holes for the ELT base unit and the antenna hole was located to place the antenna were we needed it.  Now there's plenty of room for the BNC connection.

On last  piece.  We wanted to add something to keep the antenna from bounding around, possibly hitting the fabric and or controls.  After taking measurements and coming up with a quick hand drawn part, it was created in a 3d Design program and printed on a 3D Printer.  The part was put in place and epoxy was added to secure the part.  Finally a shorter Coax cable was built, as the one provided with the ELT was extremely too long.

Total Hours: 8

Old and New ELT Plates
New ELT Antenna with plenty of room

3D Printed Part to control Antenna location

ELT Installed with new Coax

Sunday, June 24, 2018

Rudder Cables, Rear Windshield Bracket, Right Wing Cuff

Ed continued to work on the right wing leading edge cuffs.  Ed is doing some prep work before we add the epoxy filler to finish off the cuff installation.

While Ed was working on the Cuff, Michael installed the the rudder control cables that were previously made.  Currently the cables were routed to just behind the baggage area bulkhead and will remain there until after the fuselage is covered with fabric.

Rudder cables installed in the fuselage
Finally the F-2200 rear windshield bracket that was previous trimmed to size was clamped into position making sure it was centered.  A straight edge was also clamped between the two but ribs and the bracket was positioned such that it was at the same level.  Five of the six hole locations were drilled and cleco'd.  The sixth position could not be drilled while the wing folded.  Once we unfold the right wing the last location will be drilled.  Hours: 2

Rear windshield bracket installed

Saturday, June 23, 2018

Swaging, Filler, and More

Today was swage day.  8 foot pieces were cut from the 3/32" Stainless control cable for each of the flap cables.  Four 15 foot pieces were cut for the Aileron cables.  The manual gave no starting cable length for the Rudder cables, so a test run was made giving a extra for final fitting and cut.  Two cables were made with this length.  This resulted in 8 cables that needed one end dressed with thimbles and swaged sleeves.  The sleeves were dressed with heat shrink tubing for a nice finished look.

Cables cut and ends dressed
Shackles were added to each of the cables.  The control cables in the left wing were run from the control surface (Aileron up/down and Flap) through the pulleys and through the holes drill in each of  the wing ribs.  It was fun the pull on the cables and see the corresponding control surface move!

Flap control cable  installed

Aileron control cables installed
Balsa wood plugs were glued into the ends of the leading edge wing cuffs.  Once the glue dried, a final thin layer of epoxy filler was added for a nice smooth finish.  Hours: 4

Filler added to cuff

Thursday, June 21, 2018

Left cuff

More work on the left cuff, this time along the bottom edge.  Sanded a previous coat of filler, then realized that to get a smooth transition I really needed to sand some of the bottom edge of the fiberglass cuff itself.  My goal here was to get a nice smooth transition while trying to use as little filler as possible in order to keep the weight down.  This would have been a lot easier if the wing was off the plane since I was essentially working on the bottom side of the wing, but I really didn't want to bother with that. In any case, after sanding the bottom edge and adding (plus sanding) another coat of filler, we now have a reasonably smooth transition.  Hours 2.0

Sunday, June 17, 2018

Leading Edge Cuff, Control Cables, Elevator Tube

We've started hitting a lot of little things that need to be completed before covering can begin.  3M Lightweight 2 part filler was added to the bottom edge of the right wing leading edge cuff.  Once dried/cured it was sanded smooth.  The same thing was done on the top edge of the right wing leading edge cuff and a second coat of filler was added to fill voids.

Cables for the flaps were temporarily run to check for interference and a major one was found.  The elevator tube cover in the baggage area will need a through hole for the cable to pass.  We've been wanting to drill lightening holes in this part as a weight savings.  Even though we only saved 0.6 ounces, this savings will add up over time on various parts.  7/8" holes were drilled on the top surface of the tube cover, and 9/16" holes were drill on the sides.

Elevator tube cover and flap control cable with interference

Elevator tube cover with lightening holes drilled

We also cut the stainless steel control cables for the flaps and ailerons.  Two 8 foot pieces were cut for the flaps.  Four 15 foot pieces were cut for the ailerons.  Hours: 5.5

Wing control cables cut

Thursday, June 14, 2018

Leading edge cuffs

A coat of lightweight 2-part filler was applied to the upper joint between the left leading edge cuff and the front left spar (leading edge).  Once dried, the high spots were sanded down.

Michael sanding filler at the left cuff

On the right wing, the leading edge cuff had to be trimmed a bit more around the strut attach brackets so that it would fit nicely to the wing.  Most of this was done using a dremel tool with a sanding bit.  The cuff and leading edge of the wing were cleaned, and then the cuff was glued to the right wing with silicone adhesive.  Gaffer's tape was used to hold (clamp) the cuff in place while it dries.   Hours: 3.0

cuffs trimmed to fit around strut brackets
Leading edge cuff glued and held temporarily  with tape

Sunday, June 10, 2018

Leading Edge Cuff Work on Right Wing

The tape securing the left leading edge wing cuff was removed.  The securing tape on the two rear baggage area windows was also removed.

We finally started work modifying the right leading edge cuffs so they fit on the wing.  We first had to fold out the right wing and add the front wing root fairing.  The edge of the fairing marks the starting point for the leading edge cuff.  We marked the starting point and then folded the wing back.  We first modified the in-board cuff such that it cleared the jury strut mount bracket on the wing.  This required many fittings and trimmings to the the correct fit.  Once it was successfully modified it was temporarily taped in place.  The second, out-board cuff, needs to be modified to clear the main strut attach bracket.  That was started, but not completely finished.  Hours: 2.5

Ed modifying leading edge Cuff

Saturday, June 2, 2018

Wing Cuff, Pulleys, and some window work

We attached the fiberglass leading edge cuff to the left wing with silcone adhesive (DAP Dynaflex 230), and used some gaffer's tape to hold it in place until it dries.
Leading edge cuff with beads of silcone caulk/adhesive

Leading edge attached and held with brown gaffer's tape
A couple of small attach tabs were removed from the rear trim mounting plate.  We didn't need those tabs to mount the trim motor, so just cut them off to save a little weight.
Tabs indicated with red arrows were removed

We added a little caulk around the edges of the aluminum rear window openings to reduce potential vibrations of the aluminum border against its steel frame

Window border with silicone caulk applied
Next we re-installed all the cable pulleys in the wings in preparation for running control cables through the wings.   Hours: 2.5

Thursday, May 31, 2018

Fairleads and some filler work

Found one fabric attach plate where we had not yet added filler to smooth over some of the rivet heads, so some lightweight filler was added, and then sanded smooth once dried.
Filler added to fabric attach plate on left wing
Also, 6 plastic fairleads were installed in the tail section which are guides for the rudder and elevator cables.  Had some difficulty installing the metal clips at first, but then discovered a trick that helped which was to use a C-Clamp to hold the metal clip right against plastic fairlead, and then pop the clip in place with a small screwdriver.  I learned my lesson after fighting with the first few clips while just trying to use a pair of needle-nose pliers.  I was able to get them on with the pliers, but it was a fight.  The trick with the C-clamp seemed to work well, though.  Hours: 1.5

Plastic fairlead installed with metal retaining clip

Saturday, May 19, 2018

Trim Servo cont.

Today we made some adjustments to the connection between the servo motor and the trim tab to get it working with the right range of motion. We get about 30 degrees of motion in one direction, and 40 in the other which is plenty.  The stainless steel connecting rod was shortened, and we drilled a new 1/8 hole in the connecting tab at a spot that was a little lower than the original hole to get more motion.  We also reshaped the connecting tab  to eliminate any interference with the attaching clevis. Below was a test of the servo motor using a small 9V battery.  Hours: 2.0

Thursday, May 17, 2018

Trim Servo Mount Plate

The CCC-44 rivets arrived from Aircraft Spruce.  Before riveting the part in place, four nutplates were installed that matched the hole pattern in the Ray Allen trim servo.  Once completed the mount plate was riveted in place.  A temporary rod was installed to mount the the trim tab and a 9V battery was used to check the movement of the servo.  We still need to calculate the correct attach point of the servo clevis pin to get the range of motion we need, but it was nice seeing the time tab move.

Trim Servo Mount Plate Installed

We also started looking at possible mounting positions for the transponder and ADS/B antenna below the baggage area.  We have a couple of ideas we are exploring.  Hours: 1.5

Sunday, May 13, 2018

Pitot and Trim

The new pitot tube stalk was completed.  The base that Ed had welded on needed to be cut down to the correct size.  Four edge nutplates were installed on the base.  Then the length of the part needed to be cut down.  All surfaces were then deburred and the four holes needed to mount the Garmin Pitot tube were drilled.

The biggest benefit was that we cut the weight of the part by 1/2.  The original mount weighed in at 5.7 oz and the new part weighed in  at 2.1 oz.  

2.1oz (new) vs. 5.7 oz (old)

Pitot Tube complete
Started working on the trim servo mount and found that the mounting plate needed to be raised up about 0.09" to be flush with the fabric surface.  Two spacers were made from 0.09" aluminum stock.   Everything is cleco'd in place awaiting riveting.  CCC-44 rivets will need to be ordered.  Hours: 2.5