Monthly Construction Log - July 2009
| Date | |
| 1 |
Finished riveting forward fuselage belly skin (CCPQ-43 in weldments)
except at firewall and at side skin overlap. Riveted forward
fuselage frame. (Page 06F-03/-044 of the assembly manual shows (3)
AAPQ-42 and (4) AAPQ-44 going into KPFU0522 - the pointed out in the
photot should be AAPQ-44, not -42.) Reinstalled static ports with 1/4"
push-to-connect fittings and removed old lines. Need to install new 1/4"
line to static ports. Started routing trim wiring, VHF antenna cable,
and static line through center fuselage. Rotated right wing top side up,
and reset wood blocks. Started transfer drilling #40.
|
| 2 | Clecoed on step plate, then transfer drilled skin to #30. Marked 0.45" reference line on forward edge of upper aft skin. |
| 3 | Flipped wing over and adjusted blocks. Marked 0.45" reference line on forward edge of bottom aft skin. Located first hole in line with inboard rib and drilled #40. Clecoed and clamped leading edge skin into position, and taped down. Started transfer drilling into main spar #40. |
| 4 | No work. |
| 5 | Finished tranfer drilling #40 into main spar. Aligned front ribs and
transfer drilled #40, then transfer drilled all to #30. Installed access
panels, and drilled all rivet holes. Still need to drill bolt holes -
will do on bench after removal from wing. Got location of extra access
panel for Princeton fuel probe access from Glenn, but ran out of time to
install it.
|
| 6 | Transfer drilled fuel probe access panel onto lower wing skin
outboard of the tank skin. Placed centerline edge rivet as shown in
photo. Marked skin for cut-out after removal from the wing. Flipped wing
over and clecoed rear spar to blocks. Started transfer drilling leading
edge skin. The instruction say to work from the tip of the rib to the
spar, which doesn't make much sense, so I transfer drilled the spar and
started aligning and transfer drilling the ribs. With skin lined up at
the spar, the it does not lay against the forward few inches of the rib.
Will call Rans to discuss. [7/9/2009 corrected
dimensions - accidentally copied the dimensions Glenn gave me onto the
photo, which that are NOT referenced to that rivet - thanks Glenn!] |
| 7 | No work. |
| 8 | Talked to the guy at Rans who has been building the wings. His
technique for the top leading edge skin is work down the ribs, one rivet at a time. He uses an
aluminum angle and sandbags on the skin to help coax it into position.
Conveniently enough, I have a good looking 13' long 2x4 from the pallet
the wing crate was on. Clamped that to the skin, and then weighted it
with 25# of shot bags. Transfer drilled all ribs #40. Found a good trick
to push the inner ribs into position is to remove some rivets at the
main spar and slip a thin metal straightedge under the skin. Extended
the rivet line down the edge of the leading edge tip skins, then bent
them. Drilled the holes on the bottom inboard edge of the tip skin #30,
since the lower rib was already drilled #30 - they all lined up just
fine. To push the tip skin into the bend, it worked well to insert a
strip of scrap wood in front of the rib and twist it to push the tip
skin forward for a nice fit.
|
| 9 | Worked on fitting wingtip spar extensions, skins and closeout rib.
|
| 10 | Riveted fuselage floorboard and reinstalled rudder pedals. Found
that my fuselage kit did not have the brake line on the inventory.
Talked to Vicki and she is sending it out.
|
| 11 | Drilled nutplate screw holes in wing access panels. Transfer drilled #40 the remaining holes in the leading edge skin to the spar. |
| 12 | No work. |
| 13 | Finishing positioning all wing tip aluminum parts, and transfer
drilled #40. Aileron to tip gap is 1/4". Started transfer drilling #30
upper leading edge skin and tip skins.
|
| 14 | No work. |
| 15 | Finished transfer drilling #30 upper leading edge skin and tip
skins. Blew all debris out of the right fuel tank, filled with 10
gallons of fuel, and set aside.
|
| 16 | No work. |
| 17 | No work. |
| 18 | Worked out mounting location for pitot mast mount. Will move pitot mast one bay outboard from stock location due to access panel opening. Since the mounting plate couldn't go next to the rib web, decided to run a stiffener at the forward edge and tie into both ribs. Started fabricating parts for mount. |
| 19 | Finished fabricating parts for pitot mast mount. Fluted mounting plate to conform to shallow bend in lower wing surface. Marked rivet pattern on parts and transfer drilled #40. |
| 20 | Fit-up parts for pitot mast mount, and transfer drilled all #40.
Drilled all rivet holes through skin to #30. Will finish remaining #30 transfer drilling when
the leading edge skin is removed and access is easier. |
| 21 | Flipped wing over and removed leading edge skin. Transfer drilled
#30 remaining rivet holes on pitot mast mount. Removed stock pitit tube
brackets from wing ribs - will be running all lines in grommet in
forward end of nose ribs. Cut out tank opening in lower aft skin, then
reinstalled leading edge skin for torque angle fit-up. Bent torque angle
and transfer drilled. (Not as easy as it sounds...) Put a slight joggle
in the aft end of the torque angle where it goes over the edge of the
tank cover skin.
|
| 22 | Removed all wing skins, hinges, etc. from the wing frame in preparation for fuel tank fit-up. |
| 23 | Siphoned fuel out of right tank into left tank. Per the Rans update,
I will not be using the tank angles, although I may use some cork
depending on the fit. Decided to drill
the tank mounting holes in spar/aft channel before cutting holes in tank
for fittings. (The tank doesn't dry out that way.) Cut templates to size, drilled to match tank, and taped
them to
the tank. (Note - using lots of tape is a good idea to keep the
templates in place, see last photo for what my second attempt looked
like.) If
your aft channel did not come with the inboard alignment holes like
mine, drill them BEFORE putting the tank in the bay because you will need them to mark the aft templates.
The exact position of the hole is not critical - see circled hole in
third photo. Rather than use a fine Sharpie, I drilled with a #40 bit in
the hole just enough to mark the template without drilling through it.
|
| 24 | Drilled fitting holes in right fuel tank. Transfer drilled old
plexiglass from empennage assembly to tank skin, then clecoed to wing
frame to mark vent and drain fitting locations. Removed tank, installed
tank skin and plexiglass templates, then drilled tank skin for vent
and drain fittings. Drilled hole in rib for Princeton fuel sender.
Milled fittings for drain and fuel sender to 3/8" for 0.3", then cut
slot in other end.
|
| 25 | Modified fuel pickup tubes by milling four 3/16" holes and then
crimping the end. Modified vent tubes to have crimp to 0.17" and
45degree cut on long end, and 60degree cut on short end - make sure you make a set for
left/right!
|
| 26 | Elongated tank mounting holes in main spar and aft channel. Watched airplanes fly over on the way to Oshkosh... |
| 27 | No work. |
| 28 | Drilled holes for grommets in nose ribs. |
| 29 | No work. |
| 30 | No work. |
| 31 | No work. |