Wings

LH Bottom Wing Skin ( 3 hrs )

Drilled and deburred holes in LH Bottom outboard Wing Skin and J-stiffener.   Ready to dimple. With skin off, confirmed no new holes in rib flanges ! (proof I'd aligned ribs correctly with existing holes)   Worked evening session so I could take skin off.   Ready for Sam Sisk, EAA Tech Council to exam work on QB Wings Thurs morning ( his 3rd visit since build started on Empennage in Jan 2016.

Selfie - in reflection of Wing skin

Overlap inboard & outboard J stiffeners

 


Pic with phone inside Wing...confirming J-Stiffener holes were correctly positioned.

Wings

Bottom Wing Skins  ( 3 hrs )

Unwrapped the Outboard Bottom Wing Skins.  Deburred edges on LH skin, and stored RH for now.  Added J-stiffener per Sect 20-03 and -04.   Good progress - mounted w/ clecos to Wing.  Ready to match drill next.

checking as I go to be sure Ribs aligned correctly

Aaaarrrgh !  After re-check,   I'll need to remove LH Tank from Wing to search for a small leak.   Can't find any in accessible areas, but balloon slowly leaks down in few hours.  RH Wing checked  A-OK few days ago.

Wings

Elect Aileron Trim ( 2 hrs )

Leak test LH tank again.   Balloon stays inflated for more than 2 hrs, and I can't find a leak on surfaces I can access with soap bubbles.   Need to flip Wing over to check other side - esp fuel fill cap area (think I did thoroughly first time, but want to repeat).  All this to determine if need to remove tank from spar to access areas I can't reach when installed...such as back wall and outboard rib.

Installed Elect Aileron Trim assembly into Wing.  Mounted 2 Spring Brackets onto Pushrod with blind rivets.  I measured several times to insure correct position.  When installing it's very challenging to stretch Springs far enough to attach to Trim Arm.  Once assembled into Wing, confirmed clearances through full Aileron travel.

Endoscope view showing connector and wire routing

Endoscope view:  Trim arm clearance above Pushrod

Once Wing was moved to horizontal on table (vs vertical in wing cradle) the Aileron moved to neutral position balanced by springs.   Sweet !

Wings

Elect Aileron Trim (4 hrs )

Installed LH Flap to confirm fit & operation, then returned to safety of "storage" room.  Aligns with Aileron well.

 









RH tank leak test completed -- no bubbles found and balloon stays inflated at least 24 hrs.  Yay !     Rec'd from Vans the 4 AN3-13A bolts (error to not include in QB kit), so I replaced the temporary  -12A bolts.

Completed Electric Aileron Trim build, Sect OP 38-04, 05 and 06.  Drilled, deburred, dimpled, primed and attached nutplates. Took several pics inside wing to confirm clearances and setup. Some with endoscope (lower resolution).

 

 

Crimped Molex Micro-fit Pins onto 5 wires, then inserted into Molex connector.   Really challenging since tiny pins.   Test fit into mating connector inside access bay.  A little stiff first, then seemed easy to re-insert.  Discovered one of the female pins was driven out of connector.  Needs to be replaced...next work session.   Fortunately I'd ordered spare pins.  [ done 1/16 ]

   

Wings

Ailerons Adjusted to Neutral, Flap Installed  ( 3 hrs )

Sect 23 -10 completed. Adjusted LH Aileron 1st using W730 jig (template) at Bellcrank and W00026 Alignment Template at end of Aileron.  One turn of rod end on Pushrod CS00013 only needed.   Measured 64.5mm vs 64.3mm spec'd at Torq Tube neutral position. Pending receipt of Van's W730 actual template for final confirmation, but within 0.2mm (.007") is quite accurate -within 1/2 turn of rod ends.   Repeated for RH Wing with 1 turn of Aileron Pushrod, and 1/2 turn to main Pushrod.  Measuring 64.3mm and neutral at Bellcrank and Aileron with templates installed.   Not torquing AN3 bolts/locknuts since will remove Ailerons and Pushrods when I rivet bottom skins. Very satisfying for the smooth and easy movements of the Ailerons.

LH Aileron neutral position

LH Pushrod to Aileron

LH Aileron pushrods & Bellcrank

RH Aileron neutral position

 Mounted Flap to check clearances and position.   Good to GO !

Wings

Ailerons mounted  ( 1 hr )

Mounted LH and RH Ailerons to Wings and Pushrods.   Some adjustment required using washer positions (reversed location of 2 washers vs 1 ) to center aileron between hinge supports to avoid contact with rivet heads on hinge brackets.  Documented in instructions so I can repeat after dis-assembly, etc.   NOT tightening locknuts at this time since expecting some adjustments will be required to neutralize position.  Also, will be removing pushrods and Ailerons when I rivet on bottom skins...so I know they're coming off soon.

 

Wings

Pushrods Installed ( 3 hrs )

Sect 23-09:  Installed Pushrods between Torq Tubes and Bellcranks for both wings.  (I discovered Vans failed to provide W-730 template used to align bellcranks in neutral position.  When I contacted them, they emailed a dimensioned drawing (and sent the actual one in the mail I plan to use to confirm alignment).  I determined only 1 dimension was critical and some of the shapes were unnecessary - so making the template was relatively easy vs the all the dimensions w/o tolerances shown to .001".... Their engrg dwgs need to be properly dimensioned !

I left fasteners loose to allow final adjustments.   Really like having the Washer Wrenches from Cleaveland Tools...one is shown in pic at inboard rib area near Torq Tube.   These make slipping in small washers much easier - with so much less cussing.

RH Wing...pushrod connected

Very pleased with the silky smooth operation of the control linkages - extra time spent getting the brass bushing fit just right at Bellcranks seems to be paying off.

LH Wing...note fastener not tighted...yet.

RH Wing Bellcrank w/ W730 template holding neutral position

   Autopilot support bracket installed...pending Servo install.

LH Wing Bellcrank..  Loose nuts until final adjustments.