Aileron and Flap Hinge Positions

With the wings now safely located in our garage we used them to locate the position of the hinges and bellcranks on the Ailerons and flaps.  The location of wing ribs 1,2,4,5, 7, and 9 were used to locate the hinge and bellcranks.  Wood strips were clamped to the wing top and the Aileron and Flap were placed in their correct position.  A 1/4" spacer was placed between the aileron and flap to maintain the correct spacing. The aileron/flap pair was then centered on the wing with equal overhang on both ends.  Once centered, the location of ribs 1,2,4,5,7 and 9 were transferred to the aileron/flap spars. Hours: 2

Wing Transport

We were at the point where we needed to have access to the wings to continue.  The wings were being stored at the airport, so we carefully loaded them up and secured them in the trailer (each wing is held in a sling, and the frame is screwed down to the base of the trailer).  The wings were towed back home and are now in the garage.  So the garage just got even smaller.  Hours: 2

Two wings successfully made the trip home

Aileron & Flaps: Hinges and Bellcrank prep

Spent a few hours preparing hinges and bellcranks for attachment to the ailerons and flaps.  This included careful locating, marking, drilling, and deburring a plethora of holes in these parts for the rivets.  There are 5 holes in each hinge, and 10 in each bellcrank.  With all the hinges (8 total) and bellcranks (4 total), this came out to a grand total of 80 holes.  Each hole was upsized to 1/8 inch per the manual.  We also reamed out a 5/16" hole in the bellcranks for a brass bushing insert, and cleaned out the powder-coat paint from the inside mating surface of the hinges and bellcranks.  Hours: 3.5

Michael is reaming a hole for a brass bushing

4 bellcranks and 2 hinges prepared and ready to go

Final Aileron/Flap Tailing Edge Installation

The inside of the aluminum trailing edge was sanded with 100 grit emory cloth to allow a good surface for the Hysol epoxy to attach.  Only the area around the attach point was sanded.  Then, all the surfaces were wiped down with Acetone for a final cleaning.

The two part Hysol epoxy was mixed and applied to the trailing edge of the rib cap strips.  The trailing edge aluminum was re-applied and flush rivets were pulled. 

Epoxy applied and attaching trailing edge

Trailing edge riveted and epoxied in place

The epoxy was allowed to cure for about 30 minutes and then using a finger dipped in water it was smoothed for a nice clean finish.  Hours: 2.5

Smoothed Hysol Epoxy

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

Brake Master Cylinder Installation

After allowing the paint on the Brake Cylinder attach brackets the two MC-4 and two MC-5 brake master cylinders were installed using AN3-12A bolts and matching washers and nuts.  With the brake cylinders in place, the location of the attach hole in the toe brake attach bracket was marked.  The parts were removed and holes drilled to 5/16".  The brackets were re-installed and the brake cylinders were attached using the nuts included with the cylinders. Hours: 1

Brake Cylinders Installed

Toe Brake Work

Had to do a little grinding on the rudder pedals to allow the toe brake brackets to fit correctly and allow free movement.  Once the brackets fit correctly, the F-0845.0 Bushings were fit with the correct orientation indicated in the builder's manual.  The F-0845.1 bushing stops were fit in place and drilled for a CCP-44 rivet (i.e. 1/8").  The parts were bushing parts were removed and prepared for painting.  The parts were allowed to dry overnight and then everything was re-assembled and the toe bushings tops were riveted in place.  The Matco brake cylinders were next to be fitted.  Due to an interference issues with the attach bracket and the brake cylinder attach point more grinding was needed.  about 1/16" was removed from the rounded section of the attach brackets on the fuselage.  Once the grinding was done, the exposed metal was painted to prevent rust.  Brake cylinder installation will have to wait for the paint to dry.  Hours: 2.5

Toe Brakes Added