Repeat for RH Lens. Trim, Trim, and Trim some more. Then sand to get final fit. Time consuming, but I like the outcome. Used painters tape to protect Lens better during handling this time.
Saturday, April 1, 2017
Wings
RH Tip Lens ( 2 hrs )
Repeat for RH Lens. Trim, Trim, and Trim some more. Then sand to get final fit. Time consuming, but I like the outcome. Used painters tape to protect Lens better during handling this time.
Repeat for RH Lens. Trim, Trim, and Trim some more. Then sand to get final fit. Time consuming, but I like the outcome. Used painters tape to protect Lens better during handling this time.
Friday, March 31, 2017
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.
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.
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| Comparison w/ RH Lens untrimmed, vs final LH Lens |
Thursday, March 30, 2017
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" 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.
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| filled "slot" aft end RH Tip - sure glad I reinforced inside 1st |
Wednesday, March 29, 2017
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.
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.
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| the gap...but it's solid behind. So will fill flush. |
Tuesday, March 28, 2017
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".
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".
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| pic from inside showing rivets and blind rivets. Only buffed and primed flanges...so "messy" in center of rib |
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| whew..glad this Tip is almost done... except trimming end ~1/4 inch as marked   |
Monday, March 27, 2017
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.
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.
Sunday, March 26, 2017
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.
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.
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