Monthly Construction Log - November 2009

Date  
1 Transfer drilled left wing top skin #30. Drilled grommet holes in forward ribs. Flipped wing and started leading edge skin installation.
2 No work.
3 Transfer drilling #40 bottom of leading edge skin to spar and ribs. Finished design and ordered PCB for new buck-boost regulator for LED landing lights.
4 Finished transfer drilling #40 bottom of leading edge skin to spar and ribs. Transfer drilled access panels. Transfer drilled #30 bottom leading edge skin. Corrected placement of outboard nutplates on spar carry-through. Found the original source of confusion - the seat ramp skins are missing a hole at the nutplate locations. Added hole in seat ramp skins and started installing them.
5 Finished riveting seat ramp skins.
6 No work.
7 Located position for extra access panel for fuel probe, and transfer drilled. Flipped wing and pulled leading edge skin into position on top of spar. Set up twin LED landing light prototype with optics on house deck railing, then drove ~3/4 mile away to see what apparent brightness was like. Very bight - a nearly full moon paled by comparison!
8 Started transfer drilling #40 leading edge skin to spar.
9 Continued transfer drilling #40 leading edge skin to spar and leading edge skin.
10 Finished transfer drilling #40 leading edge skin to spar and leading edge skin. Started assembling tip rib and remain tip skins.
11 Finished assembling tip rib and remaining tip skins, then transfer drilled #40.
12 No work.
13 No work.
14 No work.
15 Transfer drilled leading edge skin and tip skins #30. Cut fuel probe access panel hole in bottom skin. Disassembled to start fuel tank installation. The tank has had fuel in it for several months, so it was fully expanded and tape did not want to stick to it well. Stretched packing tape completely around the tank - that was enough to hold the mounting hole templates in place. Fit tank in into wing, and marked mounting holes - tank was a very tight fit. Drilled tank mounting holes, and cut holes in tank for fittings. Cut holes for vent and drain in lower tank skin. Cut fuel probe clearance hole in outboard tank bay rib.
16 Marked slots for tank mounting bolts. Started forming tank torque angle.
17 Built up new buck-boost converter PCB assembly for LED landing lights.
18 Tested buck-boost converter - achieved proper operation with input voltage from 5V to 50V.
19 No work.
20 No work.
21 Built up more buck-boost PCB assemblies.
22 Filed out slotted holes for tank mounting bolts. Finished forming tank angle and transfer drilled. Verfied location for fuel cap opening in top skin - was at factory guide hole location. Disassembled wing and deburred wing frame.
23 Deburr/polish/clean wing parts.
24 Deburr/polish/clean wing parts.
25 No work.
26 No work.
27 Primed wing frame and all wing parts except three main wing skins.
28 No work.
29 Cut fuel scupper hole in top skin. Deburred, polished and cleaned top and bottom skins and moved to paint booth for priming.
30 Deburred, polished and cleaned leading edge skin and moved to paint booth for priming. Installed grommets for wiring into wing frame.