Monthly Construction Log - June 2009

Date
1	Transfer drilled #40 left flap hinge to wing. Started aileron assembly. Got aileron frames assembled, still need to complete transfer drilling #40 inboard end. Then will install the hinges and transfer drill everything to #30. (If doing this over, I would build the ailerons and flaps before starting the wing assembly - having the wing frames in the way makes it more difficult to find bench space...)
2	No work.
3	Finished assembling both aileron frames, then mounted hinges to frames. (Pictures were taken after scrap hinge spacers were removed.) Transfer drilled all #30, then disassembled for priming. Started deburring/polishing parts.
4	Finished prepping parts for priming. Primed all aileron frame parts.
5	Riveted aileron frames. Rolled leading on both aileron skins. (Found it worked better with a 1.75" O.D. pipe to put the bend in the right place, instead of the 1.5" called for in the instructions.) Installed skin on left aileron frame and transfer drilled #30. Connected left aileron on left wing to install wing sides of the aileron hinges, then installed hinge doublers. Note that the outer hinge doubler has one hole that is to close to a lightening hole in the aft spar - will need to move that rivet location. Transfer drilled #30 the left wing's lower aft skin, then removed wing from workbench. Started installation of the right aileron skin.
6	No work.
7	No work.
8	Finished transfer drilling #30 bottom side of right aileron skin, started on top side.
9	No work.
10	No work.
11	No work.
12	No work.
13	No work.
14	No work.
15	No work.
16	No work.
17	No work.
18	No work.
19	No work.
20	No work.
21	Finished transfer drilling #30 right aileron skin. Disassembled ailerons, and deburred both aileron frames. Deburred, polished, and cleaned both aileron skins. Put all aileron pieces in paint booth for priming, and put right wing frame on workbench. Need to move center block on workbench to clear wing rib. Will try to prime and assemble ailerons tomorrow before clamping wing frame to workbench.
22	No work.
23	Primed aileron skins and touched up aileron frames. Riveted skins to frames. One rivet location on each aileron had too little clearance for the Avex rivet to pull in nicely, so I changed it to an AAPQ-41.
24	Riveted seat deck area except seat ramp skins. Will leave those off for now to have easier access to wiring/plumbing.
25	Riveted center/forward fuselage belly skin and landing gear mount gussets except at engine mount weldments. Drawing calls for AAPQ and Avex into steel mounts - will check with Rans on that before proceeding.
26	No work.
27	No work.
28	Clamped right wing frame onto bench and squared main/aft spars. Clecoed lower aft skin to wing frame. Compared measurement from edge of skin to machined edge on spar between left/right wings (shown by red line on photo below), and found them to be within 1/64". So, if they're a little out of square, at least they're symmetrical...  :-)
29	Transfer drilled right wing lower aft skin #40. Clecoed on lower aft tip skin and tank cover.
30	Transfer drilled right wing lower aft skin #30. Attached flap hinge and aileron, transfer drilled hinges #30. Installed hinge doublers and transfer drilled #30. Removed aileron, although it is quite a challenge to get the hinge pins out. Talked to Ed at Rans about forward fuselage belly skin rivets that go into the steel engine mount weldments. He said it would be fine to use CCPQ-43 instead of the AAPQ-43/Avex rivets called for in the rivet schedule. CCPQ-43 are only $0.31/each at Aircraft Spruce, so I will be installing them into the weldments to avoid the corrosion possibilities of aluminum rivets into steel. Would really like the engine to remain attached... :-)