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

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

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

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

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

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

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