Wings

Completed Aileron Torque Tube to Bellcrank Pushrods (1 hr )

Completed six rivets each per 4 Rod Ends.  Final touch up primer applied to bare spots where tape covered orientation marks.   Looks Great !   Onto 23-04...

Wings

Aileron Actuation ( 4 hrs )

Used Template and Center Punch to designate 6 holes at ends of each tube.  Included VA-111 Threaded Rod End in place (4x) so would be drilled simultaneously.  Drilled #40 followed by #30 using clecos to hold positions.  Deburred, cleaned with acetone, and primed.   Taped over alignment marks to enable correct re-assembly.   Plan touch up at those small areas with primer after riveting.

Used rod end bearing as "handles" to install rod ends.

 

Ready to rivet, then touch up label zones.

Wings

Started Aileron Actuation  ( 4hrs )

Finished RH Wing Gap Fairing rivets.   Started Sect 23 Aileron Actuation by unwrapping LH & RH Ailerons (part of QB Wings "kit").   Temporarily mounted LH Aileron to Wing...mostly to have out of the way while I worked on pushrods.   Fabricated two CS00012 Torque Tubes to 64.25" lengths per Step 1 in 23-03.

 
 

Wings

RH Wing Gap Fairing cont'd  (2 hrs )

Riveting Gap Fairing with wing in cradle.  Great fit, and impressed how straight the trailing edge is on both wings.

Meanwhile, inflated balloon to monitor for leak
(after new sealant applied several days prior)

Wings

RH Wing  Gap Fairing  ( 4 hrs )

Finished LH Wing Gap Fairing, and started RH.   Repeat of deburr, dimple...and rivet.   Inerted six CR3212 -4-6 rivets before calling it a day...

LH Gap Fairing completed

Good progress on RH Gap Fairing

Wings

Continued riveting Gap Fairings LH Wing (1 hr )

Continued riveting Gap Fairing LH Wing.   Most can use Main Squeeze from Cleaveland Tools.   Quit early to go flying with wife - finally some decent VFR weather.

Wings

Gap Fairings on LH Wing  (3 hrs )

Cont'd Sect 20-02 Steps 1-5 for LH Wing:   install Gap Fairings.   Shifted to these while tank sealant cures from yesterday.     Final Drill #40 & #30 holes  (ie reamed).   Theirs a lot for relatively small pieces (narrow,  full length wings).  Deburred all edges and holes.  Dimpled per plans.   Fits perfect...partially riveted.   More tomorrow.

Wings

Misc...tanks, etc (3 hrs )

Leak test LH Wing Fuel Tank, and discovered 1 leak at inboard corner.   None along wing surfaces, including at fuel cap...or any of the fittings I've installed.

I decided to test LH tank now, since I was getting ready to mix ProSeal for installing the RH Wing's Fuel Level Sensor.   So...able to "patch" this leak with extra sealant.  Also applied sealant to several inboard corners on Right tank that looked "iffy" (might as well since going in trash otherwise)

RH tank with level sensor installed.   Added sealant to 6 corner locations, too.

Installed RH Fuel Level Sensor, and checked "up" position. Measured 32 ohms, so matched uninstalled resistance at this end of travel.   Need to flip wing over to confirm other direction.  Note:  I checked prior to final installation with a string tied next to float routed through drain opening...32 to 249 ohms confirmed full travel.   Installed VA261 and Plug.   I need to wait couple days for ProSeal to cure before air tests for both tanks.

Painted RH Landing Light inside area black.

Cleck'od  Flap and Aileron Gap fillers to LH Wing - perfect fit.

Wings

Misc ( 3 hrs )

Riveted Landing Light mount bracket nto RH Wing.   Added 12 SB500-6 to LH Wing (larger so can route AOA air line with heater wires in one route, and Pitot air lines in other route...including WH00012 ADAHARS harness wires for inboard 3 ribs.

Attached ground wires at LH & RH outboard Ribs.    Bent RH Fuel Level Sensor  -- took several trials to tweak for full up and down travel of 32 ohms to 249 ohms...between outboard next rib, vent line, etc.   Prefer Vans instructions accounted for clearances needed, especially for QB since no easy way to inspect (requires using my endoscope)

View via endoscope.

Wings

Wrapping up std wiring in Wings ( 3 hrs )

Replaced 1  ES00046 Molex micro fit female pin (damaged as rec'd) at CJ406J (prior to labeling, this started as ES00045 Molex Receptacle )  in the AP Servo Harness.   Connected Q427 wire to Fuel Level Sensor with ring terminal crimped on.   My wife helped me switch LH Wing and RH Wing from table to cradle...time to work on right wing horizontally.  Riveted VA146 bearing into Tank Attach Ass'ly, at 19-04 Step 5 and Fig 2.   Tie wrapped wiring harnesses along entire LH wing since easier to do while in cradle.

 

 

 

 

Again, anywhere near bolt heads on spar, I applied either lightweight split conduit, or flat spiral wrap for added protection, retained in position by wire ties at ends.

Wings

Wiring details ( 1 hr )


Crimped ES DV18-188M to W401 wire and connected to Stall Warning switch inside wing.

Installed both LH and RH outboard Wing Tip Lighting Harness Connectors.  Crimped Ring Terminal to ground wire.

Wings

More Wiring in Right Wing  ( 3 hrs )

AP Servo Harness at 19-05 & -06 completed:  inserted 12 pins into C407P connector for outboard AP termination.  Tie wrapped WH00011 & WH00013 harnesses along routing.   In any location harness was close to bolt heads on spar, added either flat spiral wrap or split plastic conduit for protection.

Wings

Wiring  ( 3 hrs )

Removed 14  SB437-4 snap bushings in ribs 1-7 in LH Wing so I could enlarge holes to 1/2" to install SB500-6 larger bushings.   Now I can route extra air line for AOA, along with it's heater wires.  Used a new 12" extension & new Uni-bit (max size 1/2")   This allowed me to drill several ribs at once, reaching inner most rib.  Thanks to Jared Solomon for his build log showing how to do this !  Deburred each hole - some hard to reach w/ deburr tool.

New 12" extension and 1/2" uni-bit.   Did 4 ribs from inboard

Back other direction, 3 ribs.    Success !

Installed WH00012   ADAHARS  harness.  This included W401 for the Stall Warning switch - routed along with WH00011 harness -  the "7th wire".  It was relatively easy now with the undersized SB removed...success !


For Right Wing, I routed WH00013  AP Servo harness.   That's a lot of wires along same path as WH00011 in this side.   Got 'er done, but need to replace one tiny Molex crimped connector that was deformed (of course its on only wire that is borderline short !)

Wings

More Wiring woes...and fixes !   ( 1hr )

Vans builder support had no reason why WH00011 wiring would not fit through LH Wing Snap Bushings.  Apparently other builders not having this problem.   They did suggest to remove the SB causing the roadblock, run wires through rib, and re-install SB (split  the SB so remove/re-install with wires installed ) - sometimes this works with undersized SB's.   So I determined something special must be up with the one SB at rib #6 causing this, and proceeded to remove it from rib.   No easy task, since in the center between an access hatch and nearest opening (outboard bottom skin not installed yet ) -- of course !       I discovered it was a SB375-3, not the SB375-4  designed/spec'd that had been installed by QB builders.   So it has an inside "flange" reducing the opening to 3/16" vs 1/4, and that ledge was the hard stop my wires were hitting !   I replaced with SB375-4 (not easy task: split the SB, work each wire into, then re-insert into Rib)     Now I readily routed all 6 wires, and I have room for the 7th from WH00012 harness.   Aaarrgggh !  

While studying other builders logs for clues to my wiring problem, I determined my choice of Garmin G3X avionics was going to create revisions to other SB sizes for other routing in LH Wing.  G3X system's ADAHARS mounts to back of displays in panel - not in LH Wing...so air line must pass through root of wing into fuselage to panel.   Only the magnetometer will mount in LH Wing.   Also, since I plan to install AOA with the Pitot, I'll need an additional air line from Pitot to wing root to instrument panel.   And a heated version must accommodate at least 2 more wires.   Vans considers the AOA optional, and did NOT equip their designs for all features available.    Whoa...would've been convenient to describe this in literature and instructions...vs touting ready for either Dynon or Garmin avionics.   So I've purchased a 12" extension to mount a uni-bit to increase the .375" holes and .437" holes to .500 holes.  Ordered more SB500-6's to replace the smaller ones.   Mitch Lock, East Coast Rep for Van's will be contacting me with details from his G3X installation into the RV14a he built.  He included the heated AOA in the Pitot.

Compared to the Empennage Kit with excellent instructions, etc...the QB Wings have been disappointing.  Missing 26 nutplates, missing 19 SB's, and now an incorrect SB installed in worst possible location.   Relatively minor, but each causes unnecessary delays/frustrations.   Seems Empennage Kit was an A+, the QB is probably a B+.  

Wings

Right Wing Wiring ( 1 hr )

Strung same WH00011 wiring through Right Wing.   Super easy with the SB500 size bushing vs too small SB375's in Left Wing.   Hoping quick/easy resolution  for Left Wing when I discuss with Vans builder support Mon.   Discovered Vans part list is short two  8-32 locknuts.   I need one each end of each wing for ground wire attachment.   2 wings x 2 ends = 4...but rec'd only 2...?   So I'll request they send these too. [ note: on Dec 12th Vans agreed to ship at no cost ]

Wings

Wire Harness WH00011  ( 1 hr )

Continued running WH00011 wires through LH wing per 19-02.    The 5th of 6 was getting tight  - so not too surprised when I could NOT get the 6th wire past the 6th Rib Snap Bushing.   Since it's exactly midway between an access hatch and open section of wing...it's a long reach.   The Snap Bushing seems too small.  I tried several ways to work it through.  NO JOY !   At first I suspected an incorrect undersized one was used by QB'ers  - especially compared to what I found on the RH Wing for exact same harness.   But when I checked in Sect 14-04 where these SB's are designated, I discovered it's supposed to be smaller than RH wing.   The LH wing has SB375-4 in the locations for this harness, and RH wing has SB500's !    Can't figure out why, since LH wing still needs a 7th wire routed from harness WH00012.    I'll hopefully get this resolved Mon via Van's builder support.

Borescope pic:  SB375-4.   Undersized in LH Wing...esp vs RH Wing with SB500 in exact same location.

Wings

Left Wing:  Fuel Level Sensor & Wiring Harness (4 hrs )

Flipped wing over so could read resistance at "empty" position.   Confirmed OK,  same 249 ohms as prior to installed in tank.  Installed fuel level sensor permanently using ProSeal as gasket.   Checked out via borescope - seemed OK, so installed VA261, AN913-3D fittings and plugs.  Also air valve temporarily in place of CAV-110.  Added balloon to fuel line -- but gotta wait for ProSeal to cure before I can pressure test for leaks.  

Full empty position - just clears bottom of tank, (and is parallel)

Started running WH00011 Wing Tip Lighting Harness from inboard to wing tip.   This required extra time to read instructions 19-02 to -06 and check out parts, etc.   Slow going 1st time running wires length of wing, but progress.

Wings

2 hrs

Riveted Landing Light bracket to top & bottom skin of LH Wing.  

Assembled Left Fuel Level Sensor.  Bent wire for float following full size drawing on 18-10.   Per Van's builder support advice, I measure output resistance at both ends of travel at 32 and 249 ohms.

 Next I did my first of several trial fits - and used my new borescope to check inside tank.  I measured 32 ohms in initial position (wing is upside down...so "full" position).  I'll need to flip wing over to examine at opposite end of travel ("empty" reading and clearances).   As shown in pictures,  I adjusted alignment (twisted wire) so float better aligns with bottom of tank.  This hasn't changed 32 ohm reading on multimeter, and can't confirm if I have 1/16" clearance to bottom of tank.   I'll need to flip wing over to determine if full travel (249 ohms), and how well or poorly aligns with bottom skin.

Prior to adjust float angle vs top of tank  (via borescope).

 
...shiny aluminum inside tank shows reflection of float.

After some adjustment...closer to parallel.  Need final tweak to gain 1/16" gap per instructions...although Van's builder support told me not required.

Showing clearance to vent line along top.

Wings

Moved LH Wing to table  ( 3 hrs )

Riveted VA195C Doubler to LH Wing, and trial fit Access Hatch VA195D.  All good.  

Sprayed 2nd coat of black on Landing Light mounting brackets and Backing Plates.  

Riveted VA146  Flange Bearing per Sect 18-05, Step 5.  Needed better access, so with assistance from my wife (thank-you !) moved LH Wing from cradle to table tops (1st time horizontal in shop).

Enabled access to Landing Light area, so cleco'd Light Bracket to F-D #40 holes in skins.   After deburr, dimpled top and bottom skins.   But, Main Squeeze with std 3" yoke can't reach any along top.  So after scratching around, I successfully dimpled via Cleaveland Tools "Tight Fit Dimpling Fixture" - w/ femle 3/32 die -  taped to tungsten bucking bar (more mass), and used C-Frame bottom set in rivet gun - w/ male die.   Ta Dah !  done...  

Painted inside of landing light area flat black per Sect 17-05 Step 2.