Flap Trailing Edge

The aluminum trailing edge for the last flap (left flap) was drilled and dimpled.  The wood cap strip on the flap was also countersunk like the other ailerons and flaps.  Hours: 0.5

Aileron and Flap Trailing Edge

Continued the work on the Ailerons, but also started working on the Flaps which are similar in the build process. The trailing edge aluminum was cut to length and the correct placement in relation to the spar was made. The holes were drilled through the aluminum and into the cap strip as indicated in the builder's manual on the remaining aileron and one of the flaps. The holes were staggered to avoid interference issues with the rivets. Once drilled, holes were deburred and the aluminum was dimpled with the custom die, and the wood cap strip was countersunk using the depth guide.  There remains one flap to be done.  Hours: 1.5

Photo-op

We rolled out our fuselage for some nice outdoor photos.

Proud Builders

Aileron Trailing Edge Work

Continued the work on the Ailerons. Ed worked on the Left Aileron.  The trailing edge aluminum was cut to length and the correct placement in relation to the spar was made.  Mike worked on the Right Aileron.  A custom tool needed to be made to dimple the trailing edge aluminum due to the tight space.  A 1/4" thick aluminum  piece was drilled and a counter sink was made to match a male dimple die.  Also, a countersinking depth guide was setup to countersink the aileron rib cap strips.  Once we were happy with the dimple and countersink on spare material, the holes were drilled through the aluminum and into the cap strip as indicated in the builder's manual.    The holes were staggered to avoid interference issues with the rivets.   Once drilled, holes were deburred and the aluminum was dimpled with the custom die, and the wood cap strip was countersunk using the depth guide.  Hours: 2.5

Tools: (L-R) Depth Guide, Male Dimple Die, Custom Female Dimple Die

Right Aileron Trailing Edge

We retrieved the flaps and ailerons that have been stored at the airport (Cox Airfield, NC81).  The aluminum trailing edge for the right aileron was trimmed to size. The distance (8.5" from aileron spar tube) was set and the location of the aileron ribs were marked.  The marks will be used later during the epoxy process.  Hours: 1.5

Setting the Aileron Trailing Edge distance

Battery & ELT Trays Installed

The battery and ELT trays were deburred and cleaned.  They were then placed in the fuselage on pre-installed weld points.  The holes were drilled, deburred and finally cleco'd in place. Time: 1 Hour.

Battery and ELT Tray in Place

Rudder & Push-pull tube cover

Trimmed, drilled, deburred, and temporarily installed (with Clecos) the cover for the push-pull tube.  This cover protects the push-pull tube from anything that is put in the baggage area. Hours: 2.5

Aluminum cover (center of pic) protects the push-pull tube

We reamed the hinge points for the rudder, installed plastic inserts, then installed the rudder with Clevis pins.  A few days ago we removed some shelving from the back of the garage which gave us the room to install the rudder.   The plane is getting bigger, and sometimes I swear the garage is getting smaller, too.  Hours: 0.5

Rudder Installed

Garage Cleanout

It's getting close to the time for attaching a wing to our project.  Our current garage layout will not work and we're having to remove a lot of the storage shelves to allow the wings to be installed and folded without hitting anything in the process.  We are distributing the displaced stored items among several locations.  There are also several wall mounted cabinets that will need to be removed and relocated for later use.  But putting a wing on our project is a very exciting thought.  Hours:  Not Logged.

Landing Gear Dolly

The garage is getting little crowded.  We are getting close to the point where we will need to attach the wings to the fuselage, so we were needing a way to move the whole project around the garage.  To allow this, a dolly needed to be constructed under each main landing gear wheel.  A quick prototype was made as a proof of concept.  The final version will be more wheel friendly, but the prototype seems to work great.  Hours: 1

Landing Gear Wheel Dolly Prototype