Aileron fabric covering

Continued work on covering the ailerons with fabric.  Applied adhesive and then attached fabric to cover the top and bottom sides of the ailerons, then shrunk the fabric with irons as usual.  Also, similar to the flaps, we used extra material at the ends of the ailerons to cover the ends of the ailerons.  We also cut out some doily shapes using lightweight pre-shrunk fabric which will provide extra protection around the hinges and control horn.  Hours: 5

Fabric glued and shrunk on one of the ailerons

Michael cutting out some protective doilies

Prep for aileron covering

We are prepping the ailerons for covering.  We learned a few things from covering the flaps, and are taking advantage of that knowledge.  We drilled a few new holes for fabric rivets because we knew (based on experience with the flaps), that a few of the holes were going to cause rivets on opposite sides to interfere with each other.  We smoothed the edges around the new holes, and applied a little extra varnish to seal the wood in those spots. 

While doing this work, we discovered something interesting.  There was a tiny little flying creature embedded in the cured fiberglass on one of the ailerons.  Looks like a small wasp.  He will forever be a part of our flying machine.  Hours: 1.0

Wasp embedded in fiberglass

Complete Flap Fabric

The leading edge tapes on the flaps were shrunk to give a nice tight fit.  Then a coat of the thinned adhesive was put on the tape to securely attach it to the flap.  The ends were dressed around the curved surfaces, cutting a few slits to keep it from bunching.  Irons were used to smooth any bubbles and/or wrinkles.

Completed Flaps on Display

Having completed the flaps, it was a good time to clean the work space.  Ed workbench also need to be lengthened and now was a good time to complete this task.

The Just Highlander manual gives some advice on how to maximize fabric usage to minimize waste.  We took measurements of the ailerons and wings and cut the fabric for the aileron to adhere to this advice.  Hours: 5 

Final Flap Tapes

The leading edge tape is the final tape to be applied on the flaps.  The tapes needed to be 5" in width.  Since this is an uncommon width we used pinking shears to cut two tapes from left-over scrap fabric.  Three coats of adhesive were added to the leading edge and finally the two edges of the tapes were glued down and the fabric tapes were shrunk with heat for a nice tight fit. Next we will apply additional glue on the leading edge to affix the fabric tape.  Hours: 4

Leading Edge Tape Being Applied

Flap covering

Made quite a bit more progress on covering both flaps.  We glued on all chord-wise tapes, and also installed doilies around the fabric backing plates.  Also fixed a small fabric tear in one location with a patch. We decided to place the drain holes in the aluminum trailing edge, which means we could use the trailing edge tape to protect those holes without adding additional doilies.  We drilled 1/4 inch drain holes in each bay of the flap (in the aluminum piece).  Would have been much easier to do this if we hadn't already covered the flap in fabric, as deburring the metal was a bit of a pain...so this is a lesson learned and we will do this in the right order when we cover the ailerons.

We glued on all the chord-wise tapes, and then attached the 3" trailing edge tape, using irons to smooth it all out as necessary.  Finally, we used an old soldering iron to burn through the fabric at the location of each drain hole.    Hours:  6.5

Flap with most tapes installed, and drain holes added in trailing edge

Round patch being added at location of a small tear

Patch complete, plus other tapes installed

More flap covering work

We measured and drew some pencil lines that are guides for areas that glue will be applied.  We also measured and cut out some protective doilies out of pre-shrunk fabric.  These doilies will be used around the fabric backing plates and drain holes, and they provide some additional protection to the fabric.  Hours: 2

A few misc protective doilies 

Flap fabric covering, cont.

We continued work on covering the flaps this weekend.  We used the extra material on the ends of the flaps to create flaps that we then folded over for covering them up.  We had to cut some V-slots in the curved area of the leading edge to keep everything neat and prevent any folds in the material.  Without knowing exactly how many slots to cut, Michael cut about 5 slots in each end on the flap he worked on, and I cut about 10 slots in mine.  Turned out it didn't matter as both worked fine and we were both able to shape the fabric around the curved edge.

Fabric covering the end of the flap

We also did a 3 stage shrink of the fabric on the flaps, which is always satisfying because it tightens up like a drum and starts to look like a real part. 

We applied reinforcing tape over the ribs, burned through the tape and fabric at the rivet hole locations with a soldering iron, and installed the rib-stitching rivets.  These rivets just add a little more insurance to ensure the fabric will always stay in place.

Rivets installed in the ribs

Life isn't perfect, and I had one "oops" moment.  The rivets near the trailing edge were a little tricky because there was not much room beneath them due to the taper, so we pulled them with the manual puller.  On one of the rivets, the puller bounced on me when the shank popped, and the sharp end of the shank hit the fabric surface, making a small tear near the rivet head. So now I have a little spot where I need to make a patch.  Not a big deal, but these things happen.

Hours: 5

To be fixed: a small tear on left side of this rivet

More Fabric work on Flaps

We continued to cover the two flaps.  We added two inches of fabric overlap on the leading edge as required.  After applying three coats of adhesive the fabric was cut and attached to the leading edge.  The Just manual and the provided pictures show a good way to add the fabric endplates for the flaps and later the ailerons.  A fabric "flap" is left on the ends and is used to add the endplates.  Hours: 2

Fabric "flap" used to cover ends of the Flaps

Flaps getting Fabric

Started working on fabric covering of the flaps.  We started by cleaning the dust off the flaps.  After hanging around for a few months, a lot of dust had to be removed.  Once cleaned, we added three good coats of adhesive on the leading edge and ribs.  The manual specifically calls for adhesive NOT to be added to the trailing edge.  After allowing the adhesive to dry, the the fabric was placed on the flap frame.  Holes were added for the two hinges points and the pulley attach point.   The fabric was glued to the the the leading edge, fabric attach plates, and finally the ribs on the bottom side.  Hours: 5

Michael and Ed working on Flaps

Flaps getting Fabric

Rudder Covering Completed!

We finished gluing & ironing all the perimeter tapes on the rudder, and used a soldering iron to burn a hole through the fabric on one side at a spot near the bottom for a drain hole (we had already glued in a plastic reinforcing ring there for that purpose).  Next up, we will begin work on covering the ailerons with fabric.  We rearranged the garage to give us a little more room for the ailerons, and cut a couple pieces of fabric that will be used to cover the two pieces.    Hours 3.0

Fabric covering completed on the rudder

Rudder Tapes Cont.

Contininuing to work on the rudder's perimeter tapes.  Three (chord-wise) perimeter tapes were glued in place and ironed smooth.  A little more adhesive was brushed on at the corners for the leading and trailing edge tapes, which will be glued down next.  Oh yeah, also had a nice accidental splash of glue on myself and the floor, so took a little time to clean that up, too.   Hours: 2.0

Rudder Perimeter Tapes

We are now working on the the perimeter tapes on the the rudder.  We marked the location and added three coats of U500 adhesive.  Once dried, we attached the chord-wise perimeter tapes.  Hours: 2

More rudder work

Over the past few days we've continued work on covering the rudder.  Fabric was glued and shrunk on the 2nd side, and we've been applying some of the finishing tapes and protective doilies to the surface.  Next we will start working on the perimeter tapes.  Hours: 5.0

Covering the rudder, cont

We finished gluing and shrinking fabric to one side of the rudder. We then continued covering the rudder by cutting a 2nd piece of fabric for the opposite side, and started gluing it to the perimeter tubes. Hours 3.0

One fabric sheet attached, 2nd sheet cut to shape for the rudder

Rudder Covering

We started gluing a sheet of fabric to the perimeter tubes on one side of the rudder.  Hours: 1.5

Gluing sheet of fabric to rudder