Wing Tip Brace Installation

The two Wing tip braces were clamped into place and the mounting holes were drilled.  All the holes were deburred and the mating surfaces of the brace tubes, spars and wood ribs were cleaned and sanded.  Hysol structural epoxy was applied at the mating surfaces and the two parts were riveted in place on the left wing. Hours: 2

Two Brace Tubes installed

Zoomed out View of Braces

Wing tip brace fabrication

We fabricated 4 aluminum pieces that will be used as braces for the wing tips.  These were constructed from aluminum tubing (1/2 x 0.035") by measuring and cutting the tubing, flattening the ends in a vice, and then bending the ends to 45 degrees.  All parts were also deburred. Two pieces (of different lengths) are needed for each wing, and we built two sets so that we would have enough for both wings.  Hours: 2.0

Flattening the end of the brace

Bending the end to approx. 45 degrees

Drag Tube Gussets

Today the drag tube gussets were installed in the left wing.  The mating surfaces were first sanded remove oxidation and roughen the surface.  The surfaces were then wiped down with acetone to remove residue and any remaining oxidation.  Hysol adhesive was applied to the edges of the gussets, at they were secured in place.  An additional fillet of adhesive along the drag tube and spar joints was applied.  After the epoxy had time to setup a little, the fillets were smoothed with a wet finger for a nice appearance.  Hours: 1.5

Michael smoothing the Hysol Fillets

Fillet at station 6 complete

Starting Wings

We are now cleaning and rearranging the garage to start work on the Wings.  We've been storing the wings in our shed and today we removed the left side wing and moved it into our heated garage so that we can start work on it.  Hours: 1.5

Ed standing between the Fuselage and Wing for Scale

Flap Fabric Backing Plates Installed

The fabric backing plates were epoxied and riveted in place.  After allowing the epoxy 24 hours to cure lightweight filler was used to smooth the transition from the backing plate to the leading edge and ribs.  This completes the pre-fabric work on the flaps.  Hours: 3

Fabric backing plate near flap control horn

Happy builders with two completed flaps

Flap varnish

Applied epoxy varnish (mix used was 1 part varnish, 1 part catalyst, and 3/4 part reducer) to the wood surfaces of the flaps. We then waited for them to dry about 30-40 minutes, and applied a 2nd coat of varnish.  Hours=1.5

Fabric backing plate work for flaps

We measured and positioned the fabric backing plates on the flaps, then drilled the holes for the attaching rivets.  Next we removed these plates, countersunk the holes on one side (since we will be using countersunk-rivets), and deburred the parts.  Hours: 1.5

Flap Pre-Fabric Work

For the flaps, we decided to switch jobs.  Ed worked on creating the aluminum fabric backing plates.  They were created based on templates in the builders manual.  A total of six backing plates were made.  Mike located and drilled the flap ribs for the fabric rivets. Three holes on the top of each rib and three on the bottom of each rib.  Hours: 3

Ed fabricating Backing Plates

Mike Drilling Flap Ribs

Three Holes per Rib

Aileron fabric backing plates

Permanently attached aluminum fabric backing plates to the ailerons by applying a thin layer of Hysol adhesive, and riveting in place. The next day, after the epoxy had cured, we applied lightweight 2-part filler to smooth the transitions between the fabric backing plates and the surfaces beneath them.  Hours: 3.0

Aileron Wood Preperation

The wood ribs of the two Ailerons were coated with SuperFlite Epoxy Varnish.  Two coats were applied to all exposed wood surfaces.  Hours: 2.5

Fabric backing plates

Construction of the aileron fabric backing plates was completed.  Some minor trimming will still be required on two of them to match them up with the edge of the ailerons.  The fabric backing plates were drilled and temporarily installed (with Clecos) to the ailerons.  Hours: 1.5

Aluminum fabric backing plate temporarily installed

More Aileron Pre-Fabric Work

Two more Fabric backer plates were fabricated.  These two go near the aileron control horn.
Hours:1

Two Aileron Fabric Backer plates

Aileron Pre-Fabric Work

Today Ed and I decided to tackle different parts of the pre-fabric work on the ailerons.  Ed located and drilled the holes for the fabric rivets on the ailerons.

Holes drilled in Rib capstrips on the Ailerons

I worked on the fabric backer plates.  Four backer plates were marked, drilled and cut to match the templates in the manual for the aileron hinges. Hours: 2.5

Four Aileron Hinge Fabric Backer Plates

Flap and Aileron: more filler work

Applied more lightweight filler on the flaps and ailerons, then sanded it down to smooth out the transitions as well as to fill in some defects (voids) that were in the fiberglass leading edge pieces.  We finished this filler work on all 4 pieces (2 flaps and 2 ailerons).  Hours: 5

Filler (bluish-green ares) applied

After sanding: nice transitions between ribs and the edges

PFD (Plane Fun Days) Fly-In in Brasstown

This past weekend, we visited our friends in Brasstown, NC for their annual Just Aircraft Fly-in.  Saw a lot of great planes (Highlanders and Superstols) and got the chance to take a ride, too, during one of the games.  Got the chance to see the balloon pop contest, and the limbo contest.  More events were held the next day (Sunday), but we headed back to Raleigh Sunday morning so missed out on those.  At night, they even had some catered BBQ and a band for entertainment.  Big thanks to Billy and all the rest that helped put on this event!

Plane Fun Days Fly-in @ Brasstown, NC

Michael (in right seat) returning from a flight

Flying under the ribbon for the Limbo contest

Ed (in right seat) after Balloon Popping Event