Wings

LH Tip Lens  ( 3 hrs )

Sanded trailing edge of RH Tip since epoxy filler had cured.  Perfect now -- no "gap" (ref recent post).  Took lots of trimming and sanding and more sanding to get LH Lens fit just right.    Then the big challenge to drill without cracking (wish you could start with holes, then trim !).  I insured part stayed warm via electric heater, and used the "plastic" drill followed by CS to fit the AN507 6R6 screw flush.   Yay !   NO CRACK....   Riveted on the nutplates, then mounted Lens.  Done -- now Repeat for RH Lens.

Comparison w/ RH Lens untrimmed,
vs final LH Lens

 

Wings

RH Tip and Lens  ( 4 hrs )

Filled "slot" at aft end of RH Tip (reference earlier recent posts) with epoxy mixed with microlight.  note: previously reinforced inside with cloth/resin anticipating this gap once I cut off 1/4".  I'm sure glad I noticed this on RH Tip, since LH Tip was A-OK at aft end.  Finally, it was time to cut the polycarbonate Lens...which ended up being less traumatic than anticipated.  To prepare, I used a portable electric heater to warm the part up (warm to the touch), since garage was only 63 deg.  Using a dremel with fiber cut off wheel worked well - essentially the material "melts" - there was minimal dust to cut apart the LH/RH thermoformed shell.  I kept the heater on as I trimmed the LH Lens.  Per Van's Step 3, I trimmed front and outbound ends to establish initial fit, then marked and trimmed off perimeter.  Using a small drum sander in dremel allowed me to quickly trim to a line.   I'll hand sand tomorrow to get final fit...then Repeat for RH Lens.   Note:  Scrap pieces allowed me to practice with plastic drills and countersink (Aircraft Tool Supply Zero Flute Countersink 3/32-1/4").   Reference VAF for excellent tips on cutting polycarbonate.

 
 

filled "slot" aft end  RH Tip - sure glad I reinforced inside 1st

Wings

LH Tip Rib ( 4 hrs )

Riveted Rib into LH Tip - 6 blind rivets and 13 flush rivets.  Re-installed to mark aft edge for trimming.  Did both LH and RH aft edges - each needing about 1/4" trimmed off.  Fortunately, with the RH Tip I noticed earlier the top and bottom skins would likely separate when I trimmed off that much (the LH was A-OK) due to a void.  They didn't get original cloth and resin fully into aft end.   So I added about 3/8" of cloth and epoxy inside at wedge end.   Once trimmed off, a gap clearly shows this was critical !  I'll fill with epoxy w/ flox now, but it's very solid.

the gap...but it's solid behind.  So will fill flush.

Wings

LH Tip Rib ( 4 hrs )

Finished RH Tip Rib installation with 6 blind rivets installed while mounted on wing ( best "jig" ).  Then removed Tip from Wing to install the remaining AN426  3-3.5 rivets.   Good result, so moved on to LH Tip Rib...basically repeat.  Drilled 19 #40 holes, with 6 enlarged to #33 for the MK319 blind rivets.  Countersunk all holes - all while still mounted to Wing.   Ready to deburr, prime and rivet next.   Planning to trim ends of each Tip when both are "ready".

pic from inside showing rivets and blind rivets.
Only buffed and primed flanges...so "messy" in center of rib

whew..glad this Tip is almost done...
except trimming end ~1/4 inch as marked

Wings

RH Tip adding Rib ( 2 hrs )

Celebrated my daughters 33 Birthday today - geesh, I'm getting old !  Countersunk #40 holes for rivets, and #33 holes for blind rivets.  Added some fiberglass cloth & epoxy resin into aft end of Tip - I was concerned when I cut about 1/4" off  of the end to be flush with Aileron, there will be little material to nothing holding top and bottom together at end of Tip.

Wings

RH Tip ( 2 hrs )

Re-installed RH Tip - great fit and alignment (whew !).  In order to install Tip Rib per next Steps 1-3 (Sect 24-04) needed to remove Tip first so I could remove aileron.  Good thing I was only using about 25% of the mounting screws.  Then re-installed Tip so I could align Rib into Tip while mounted to Wing.   Sure glad I tied a string to the Rib first, since I managed to "drop"  the Rib while position and tweaking.  I would have gotten to remove the Tip again to recover the Rib deep inside Tip.   Van's instructs to remove the Rib after only drilling a hole at each end, marking centerline on Rib, then re-align Rib back into position via holes drilled through Tip only.   Instead I simply drilled all the holes with the Rib locked in position...way easier.

 

Wings

RH Tip  ( 3 hrs )

Finished RH Tip, ready to install to confirm alignment (42 nutplates, 84 rivets later).  Versus Vans instructions in Sect 24-03 steps 8-10, I prefer to rivet nutplates to fiberglass first, then use #40 CS with the pilot which fits perfectly inside #6 threaded hole of nutplate. This avoids misshapen countersink if done prior without guide of installed nutplate.   Also using the air drill provides best finish to CS, since it "shaves" away material - and is quick !

 

Using two nutplate templates moves the process along quickly.

Wings

RH Tips ( 2 hrs )

No building most of this week while we transferred my dad from Assisted Living into a Skilled Nursing facility - lots of packing & unpacking, etc.  My brother visited from Calif during the week to assist getting the move done.  Back to building by repeating Sect 24-03 Steps 8-10:  started the RH Tip w/ #40 holes - cleco'd (its time consuming to get alignment -- but finally it was ready)  Then drilled #27 holes first at every other #40 cleco.  Using #30 cleco's "works", but since slightly loose I was extra careful to insure ALL were enlarged with proper Tip to Wing alignment maintained.

note alternating cleco sizes as I enlarge holes

Wings

Complete LH Tip  ( 2 hrs )

Machine countersunk for #6 screws using micro-cage.  Re-installed to Wing with perfect fit.

Wings

LH Tip  ( 3 hrs )

Steps 9-10, Sect 24-03 for LH Tip almost completed with 42 nutplates, 84 rivets.   Only needing to machine countersink for #6 screws (I'll be using installed nutplates as guide using #40 CS bit), then I can re-install to confirm alignment stayed same.

Wings

LH Wing Tip  ( 2 hrs )

Match drilled #27 holes in Wing and Tip, then removed Tip from Wing to deburr and dimple the Wing for #6 screws.  Used nutplate as template ( w/ #6 screw inserted from backside) to drill #40 rivet holes.  Going well, but needed to stop for other errands today.

I chose to leave Tip installed so I could "match drill" #27 holes.  Seems better than instructions which have you remove and do separately.  Since the #30 size cleco's are a little loose, I left a few of the original #40 size cleco's installed (distributed top, middle & bottom) to insure the Tip didn't move. 

Nutplate template.  After 1st hole, retained with cleco to drill second hole.

Wings

LH Wing Tip  ( 2 hrs )

Per Sect 24-03, Steps 7 & 8:  Drilled #40 holes and "cleco'd' LH Wing Tip after aligning.  Tricky getting alignment correct with Aileron.  It took me probably one extra hour to fuss with position while checking and re-checking with a straightedge and my calibrated eyeball.  Wow...this will be a LOT of nutplates !

 

Wings

Wing Tips ( 4 hrs )

Completed trim steps for both LH and RH Tips per Sect 24 -02.   Very satisfied with fit - but required several iterations to get the 3/16" gap to Ailerons since I proceeded cautiously (not very easy to put material back on the edges).   The Tips fit very well into leading edge.

3/16" gap

3/16" gap

Wings

Wing Tips  ( 2 hrs )

Finished installing AN3 bolts and screws for LH Fuel Tank.  Torqued to 42 in-lbs (28 plus 14 for friction of locking nutplates), then applied yellow torque seal.  Installed Ailerons, to be ready to align with Wing Tips.  Cut off excess flange on LH Tip, leaving just bit more than 1/2".  Dremel with 1.5" cut off wheel works better than die grinder -- mostly so compressor doesn't run nearly constantly. Didn't get to aft portion...next

Wings

LH Fuel Tank re-installed ( 1 hr )

During discussion with Gus, Van's Builder Support,  we concluded the very slow leak must be due to a "porous" balloon.  So I replaced the latest balloon, and 2 hrs later -- NO Change.   So apparently all along the leak was from the balloon skin (permeable).  Note:  this happened with 2 prior balloons on the LH Tank - but not on the RH Tank.

Extra balloon as reference... both stayed fully inflated 2 hrs

I re-installed the fuel tank.   It was much easier than I'd imagined.  The dimpled holes around the perimeter aligned readily, and the bolt holes also matched up.  I'm only about 1/2 done "screwing", but it feels good to be over this hurdle.   Since you can't reach approx 50% of the rivets and joints on the QB Wings w/ tanks pre-installed, I needed to be sure there were no leaks.

Note boards under cradles to lift tank to Spar to re-attach

Wings

LH Fuel Tank...Leak ?  ( 2 hrs )

Removed 21 AN3 bolts along Spar to Tank, and 77 Screws along Skin perimeter.   Supported tank until all removed.  Remaining plywood was perfect "shelf" on Wing cradle to support the tank cradles.   I used some thin, relatively soft epoxy stir sticks to assist Skin off of dimples.   It was easier than I'd imagined (hope relatively easy to re-install...gulp!).

After thorough inspection with very soapy bubbles, I cannot find a leak !   Expected at either outboard end Rib, or along Z Brackets.    NONE anywhere - I even re-checked all the surface top and bottom rivets, and at fuel cap.   Yet the balloon slowly lost pressure over 5 hrs.   Atmospheric pressure was holding steady, and the room temp was stable.   When I checked the RH tanks more than a month ago,  the balloon held pressure for 2-3 times longer ( I essentially could detect no loss of balloon size).   I'll call Van's builder support Monday to explore next step....?

NO LEAKS !

clear tape over fuel cap

after 5 hrs... not totally deflated, but almost.

Wings

LH Fuel Tank ...Leak ? (1 hr )

Fabricated cradles for LH Fuel Tank removal ...used plywood from Van's empennage shipping crate.  Started removing some screws and bolts.

Wings

RH Wing Skin ( 3 hrs )

Finished last 22 rivets on RH Bottom Outboard Skin.  Cleaned off markings.  Reinstalled aileron pushrods and torqued.  Discovered forgot to add 8 nutplates to the 2 access openings - good thing easy to do after skin was riveted on !   Section 20 is now done.  Also prepped for removal of LH fuel tank so I can identify and fix small leak.

inside Pic to insure aileron trim servo springs are still correct.

Wings

RH Bottom Outboard Skin  ( 2 hrs )

Nearly finished RH Bottom Skin - only 22 more rivets along Main Spar remaining.   Certainly satisfying to see how good this is turning out.

Took a selfie...who's the old guy ?

Wings

RH Lower Outboard Skin ( 3 hrs )

Nancy assisted again with RH Bottom Outboard Skin rivets - this time we did 165 in 3 hrs.   I can do the remainder alone, too.

Wings

RH Wing Bottom Skin ( 4 hrs )

Returned from whole month of February in Arizona and California.   Back to building !   Lengthened 2 wires to AP Servo Harness at outboard installation location that were several inches shorter than all others in harness by splicing in needed length.  These were in the way to access the servo and aileron bellcrank. See Sect 19-06.  Used ES320559 Butt Splices with #22 wire for C1034 (wht) and C1035 (wht) wires (these connect to molex at Aileron Trim Servo...for feedback).   Now they're bundled with all other wires in vicinity, providing better access to AP Servo.  

Nancy assisted as 'Rosie the Riveter' again for the RH Bottom Outboard Skin W00005-R.  She's getting really good, too.  Good progress considering starting with longest reach to Rear Spar, and around Flap hinge bracket.   Only 80 done, but faster than 1st time on LH Wing!