Fuel Tank Gap Rib Final Install

After cleaning and sanding the mating surfaces, the Fuel Tank Gap Rib was epoxied and riveted in  place using the Hysol structural epoxy.   A section of cap strip between the Gap Rib and the leading spar was carefully cut to size.  After sanding and cleaning the cap strip and fiberglass tank the cap strip was epoxied and held down with weights until the epoxy cured overnight.

Fuel Tank Gap Rib and Cap Strip Epoxied in Place

Next we started gathering the parts for attaching the aileron pulley assemblies.  We checked the aileron deflection with a angle meter, checking for 30 degrees either way.  We noticed we easily get the 30 degree down deflection, but having to tweak the opening on the fiberglass aileron leading edge to allow full 30 degree up deflection.  We're trying not to remove too much material, so it's a tedious on/off process  to slowly creep up on a little more than 30 degrees.  Hours: 3

Measuring Aileron Up/Down Deflection

Fuel tank gap filler rib

A short rib that will be attached between the fuel tank and the trailing edge (providing a surface for fabric attachment) was readied for installation.  It will be installed half way between the ribs that are on each side of the fiberglass gas tank.  The rivet holes for attachment were drilled, and the trailing edge aluminum was dimpled for counter-sunk rivets.     Hours: 0.5

Right wing flap and aileron hinges

Installed the flap and aileron hinge plates for the right wing.  We were more careful this time when drilling through the ribs for the flap hinges by drilling through one hinge plate and the rib before lining up the 2nd hinge plate.  This helped guarantee that no holes were accidentally drilled off center, as we didn't really want to make another hinge if we didn't have to.

The hinge plates and mating surfaces were scuffed and cleaned, and then were epoxied and riveted in place.  Below is a picture of one of the hinges.  Six hinges total were installed (three on both the aileron and flap for the right wing).   Hours 3.5

Aileron hinge riveted and epoxied in place

Right Wing aileron hinge

Drilled holes through the right wing ribs for attachment of the aileron hinges.  Made a mistake on one bracket as the two halves of the hinges did not line up perfectly when drilling, so created oblong holes on one of the hinge plates.  We fixed this by making a new aluminum hinge bracket from 0.063 aluminum.  The manual says to simply swing one bracket plate out of the way before drilling, but that's not as simple as it sounds with everything attached and clamped in place.  Hours 1.5

Flap/Aileron Alignment

We continued working on the alignment of the right flap and aileron.  We used 1/8" shims between the wing trailing edge and the flap/aileron.  We had to check at various points since this measurement varies along the trailing edge.  We also made sure the attach brackets were centered on the ribs top to bottom and they were clamped in place.  Hours: 1

Aileron/Flap Mount Bracket

 Holes were cut in the wing trailing edge to accept the Aileron and Flap mounting brackets.  Like on the previous wing, the holes locations were marked and then cut using a vibrating multi-tool.  This left a very narrow hole.  The holes were widened using a Dremel Cutoff wheel followed by round and straight files.

Holes cut in wing Trailing Edge

 We started aligning the the flap and aileron on the wing.  We still have more fidgeting with the location before drilling.  Hours: 3

Aileron/Flap location has begun