RH Fuel Tank - Vent Line/T-405

-Cut vent line to length & straightened

-Flared end, tidied up and fitted AN nut & sleeve

–Would have liked a better flare, it’s fine for the vent line but I think i’m gonna invest in a better flaring tool for future

-Marked recently received angle for T405 & started rough cutting

Manual Reference: 7-6

RH fuel tank - Skin dimpling

-Edge deburred tank skin & baffle

-Dimpled tank skin rivet holes

-Again struggling to find bits, this time the aluminium tube for the tank vent line, borrowed from the fuse kit however i’ll have to have a good look for other missing bits

Manual Reference: 7-6

RH Fuel Tank - Deburring

-Made T-714 clip

-Removed cap assy and countersunk flange

–

-Hole deburred tank skin, cleaned adhesive residue off skin, turned out to be much more effort than expected, i’m gonna have to get some MEK to make this easier in future

-Hole Deburred Ribs, Baffle, Stiffeners & Z-Brackets

Manual Reference: 7-6

RH Fuel Tank - Cap/drain flange drilling

-Deburred & dimpled/countersunk IB rib & access panel ring

-Cleaned up IB rib & access panel ring & riveted together with nutplates

-Used rod end screwed into drain flange to center on hole and drilled to skin

-Drilled Fuel cap flange to skin using cap to center in cutout

Manual Reference: 7-6

RH Fuel Tank - Access Panel

-Disassembled tank, and removed vinyl 

-Photocopied my plan sheet detail for the 405/410 drilling, scaled it to the correct size and used it to drill the T-410 reinforce plate, turns out I used the angle i was gonna borrow from the fuse kit on the firewall so i’m gonna have to source some more angle for that, I’ll come back to it later

-Fabricated my lost T-410 using my fuel tank access panel I’m not using anymore & match drilled it from the other one

-Marked, chain drilled & cleaned up hole in IB rib for access panel

-Drilled OB T-410 to rib

-Marked & Drilled T-708 access panel to rib

-Clecoed T-407 ring to assy and drilled nutplate holes to rib

Manual Reference: 7-6

RH Fuel Tank Skin Countersinking

-Peeled back vinyl on aft fuel tank and countersunk spanwise skin holes

-After contacting Van’s about lost capacitive sender paperwork they advised that they would suggest reconsidering capacitive plates, so ordered float senders & will fit those on this initial install & will have to rework the other side

-Marked component positions & started disassembling tank

-Due to a cutting error made on the left side will have to borrow angle from the fuse kit for the t-405 & reorder later, also have lost a t-410 reinforcing plate so will have to fabricate one of those.

Manual Reference: 7-6

RH fuel tank drilling

-Fitted & Drilled stiffeners to skin

-Removed components from spar & clecoed together in stand

-Drilled skin to ribs & baffle

Manual Reference: 7-5, 7-6

RH Fuel Tank Stiffener Fabrication

-Cut & cleaned up fuel tank stiffeners

-Fluted & straightened IB/OB ribs

-Mounted fuel tank ribs to baffle and final drilled to baffle/Zbrackets

Manual Reference: 7-5

RH Fuel Tank Baffle-Z bracket-Spar Fitting

-Mounted tank to spar, aligned and strapped in place

-Drilled tank skin to W-423 splice/joint plate

-Drilled inboard Rib – Tank Baffle – Z Bracket 

-Removed outer Leading Edge & drilled Outboard Rib – Tank Baffle – Z Bracket 

-Separated skin/inner ribs from the tank end ribs & baffle & removed

**Note – Figured out why I had such a hard time fitting the ribs into the skin, turns out I had missed fluting the tank ribs, so i’ll have to do that before I refit & drill the assy

-Drilled all remaining Baffle to Z Bracket holes

-This now has all the Z Brackets drilled to the baffle & spar so I can now continue per the manual.

Manual Reference: DfD-0021

RH Fuel Tank Z-Brackets

-Had some time so decided to get back into the fuel tank

-Firstly there were mud wasp nests in the spar to fuse attach holes so thoroughly cleaned those out

-Countersunk all Z brackets & IB spar at Z bracket attach

-Salvaged almost enough k1000-3 platenuts from old Z brackets but had to substitute a few for the interchangeable MS21047L3 platenuts, riveted those to the Z brackets 

-Riveted inboard platenuts to spar using blind rivets (refer DFD-22)

-Bolted all Z brackets to the spar

Manual Reference: DfD-0021, DfD-0022

Finishing Firewall

-Continued firewall riveting

-Riveted all brackets on

-Tidied up some bucking bar damage on 601j brackets and touched up with alodine pen

-Apart from rivets for cutout to be done later the firewall is done

Manual Reference: 7-11

Firewall RHS Riveting

-Built a quick cradle to hold the firewall and make it easier to work on

-Riveted Right hand side of firewall together

Manual Reference: 7-11

Right Flap Completion

-Riveted bottom skin-spar-hinge

-Right Flap Complete

Manual Reference: 7-11

Right Flap Closing up

-Finished riveting flap skins to each other

-Clecoed 706B to inboard rib, drilled to platenut, countersunk and riveted together

-Riveted both end ribs to assembly

-Slid spar in and pop riveted spar to ribs

-Drove top row of skin-spar rivets

-Riveted 706 a & b brackets together

-All thats left is to squeeze bottom row of skin-spar rivets

Manual Reference: 7-11

Riveting Right Flap

-Riveted another bay and a half completing internal ribs

Manual Reference: 7-11

Right Flap Starting Assembly

-Riveted 706A to spar

-Removed fwd rivet from inboard rib nutplate that i mistakenly fitted earlier

-Found that although primer looks much better on this side its quite soft and scratches easily, doesn’t appear to have etched properly, my guess is it wasn’t thinned enough for the gun

-Riveted ribs to rear skin spar

-Started riveting ribs to skin and skins to each other working from the middle out, completed 2x bays

Manual Reference: 7-11

Left Flap Riveting

-Riveted all internal ribs to skins

-Riveted skins together at rear spar
-Found that some offcuts of kaizen foam from my toolbox made holding the bucking bar in place easier

-Realised I was meant to leave one of the bearing attach platenut rivets to go through the 706b so removed the rivet, mounted 706b to 704 rib and riveted together
-Started riveting inboard rib to skins but struggling to get the back of the aft 2 rivets to buck them

-After some reading found that its commonplace on the inboard rib to replace the aft 2x top/bottom & rivet adjacent to platenut with mk319-bs blind rivets, so squeezed those rivets
-Fitted spar and blind riveted spar to ribs
-Fitted hinge & squeezed bottom row of rivets
-Drove top row of rivets
-riveted 7061&b together
-The left flap’s done

Manual Reference: 7-11

Right flap prep & priming, starting left flap riveting

-Removed vinyl and hole deburred right flap
-Edge deburred right flap
-Removed small amounts off edge/around hole corrosion
-Dimpled
-Primed all remaining bits, came up much better than last time, must not have been thouroughly mixed last time.

-Clecoed 706a/b to spar and riveted to spar
-Drilled & riveted rod end nutplateds to both side inboard ribs

-Started riveting ribs to skin
  

Manual Reference: 7-11

Left Flap prep/priming

-Continued deburring of right flap
-Found a fair bit of light surface corrosion on skin edges and around holes
-Removed corrosion
-Dimpled as required 
Primed with P99 wash primer i’m trying out, didn’t come out as well as I had hoped with a fair bit of running but by the end got it figured out and hopefully I can do better next time
-Run out of time to work on the other side

Manual Reference: 7-11

Flap Bracket drilling

-Partially assembled both flaps in order to mount FL-706A & B brackets
-Clamped and match drilled brackets to spar, end rib and each other

-Opened up rod end attach points to 1/4″ but cant find the platenuts so that’ll have to wait
-Removed vinyl and started deburring & dimpling

Manual Reference: 7-11

Flap Countersinking

-Countersunk lower flap spars
-Hole deburred & dimpled remaining flap spar
-Deburred hinge
-Bent FL-706Bs brackets

Manual Reference:

Right fuel Tank Assembly - Continued

-Finished drilling the Z-Brackets to the spar
-Removed brackets

-Unfortunately when i previously restarted my brackets on the left side i didnt reorder the nutplates, so i needed to try and locate the old brackets and remove the nuts from them
-Removed nuts from old plates

-Still short 4x nuts so i’ll have to order more but i can make do for the time being
-Also couldnt’t find my nutplate drill gauge so I made a new one and started drilling z-plate holes
-Drilled all the Nutplate holes but also can’t find my 3/32 countersinking cutter so can’t really do much without that

Manual Reference: DFD21

Right Fuel Tank Assembly

-Spent a while tidying garage up and figuring out where i was up to.
-Recieved a new rear baffle after previous issues also got another 200 clecoes in the order
-Properly clecoed right fuel tank ribs in place

-removed vinyl from rear baffle (carefully this time) and clecoed that in place
-Z brackets were already drilled
-Bolted brackets to spar

-Back drilled first 3 brackets to spar

Manual Reference: DFD21

FIREWALL RIVETING

-REASSEMBLED FIREWALL WITH CLECOS
-STARTED TO RIVET FIREWALL TOGETHER

Manual Reference: 8-2

PREP/PRIMING FIREWALL COMPONENTS

-HOLE DEBURRED ALL STIFFENERS, PLATES & BRACKETS
-ALUMIPREPPED, ALODINED & PRIMED ALL STIFFENERS & PLATES

Manual Reference: 8-2

FABRICATING FIREWALL COMPONENTS

-FABRICATED F-601-E AND DRILLED TO FIREWALL ASSY
-OPENED UP F-601TD BRAKE PLATE CENTRE HOLES TO 7/16″
-DRILLED PLATENUTS TO F-601Z FUEL PUMP DOUBLER & FIREWALL
-DISSASSEMBLED AND COUNTERSUNK ALL REQUIRED PARTS

Manual Reference: 8-1

ASSEMBLING/DRILLING FIREWALL

-AS I’M STUCK FOR THE TIME BEING WAITING FOR BITS I JUMPED TO THE FIREWALL AS I CAN WORK ON THIS IN MY FREE TIME AT WORK WITHOUT AFFECTING ANYTHING ELSE
-MOUNTED ALL STIFFENERS, SPACERS & GUSSETS TO THE FIREWALL AND DRILLED ASSY TOGETHER USING BOELUBE TO TRY AND KEEP MY DRILL BITS GOOD
-ALREADY FABRICATED F-601-P SPACERS SO MONTED AND DRILLED IN ASSY
**FORGOT TO GRAB MY ALUMINIUM ANGLE SO LEFT OUT THE F-601-E AND ITS HOLES TILL I CAN GET THAT BIT
-FILED & TIDIED UP F-601J & F601N EDGES TO FIT AS REQUIRED
-CLAMPED AND DRILLED F-601-J ASSYs TO FIREWALL 
-DRILLED F-601TD BRAKE PLATE
**F-601TD BRAKE PLATE STILL REQUIRES CENTRE HOLES TO BE OPENED UP TO 7/16″, I CANNOT FIND MY UNI BIT SO THIS CAN BE DONE LATER
-CLECOED & DRILLED FIREWALL RECESS TO FIREWALL ASSY (THE FIREWALL RECESS WAS A PAIN TO FIT DUE TO THE FLANGES NOT BEING EXACTLY RIGHT BUT AFTER A BIT OF WORK GOT TEM TO SIT FLUSH TO THE FIREWALL)
-FITTED AND DRILLED F-601Z FUEL PUMP DOUBLER TO FIREWALL
**DONT HAVE PLATENUTS SO THEY’LL BE DRILLED TO FIREWALL LATER

Manual Reference: 8-1

DRILLING FLAPS

-DRILLED FLAP SKINS TO BOTH FLAPS
-FOR SOME REASON I REMOVED THE CUTTER FROM MY #40 MICROSTOP SO I’LL COUNTERSINK TO SPAR LATER
-DISASSEMBLED & DEBURRED/DIMPLED/PRIMED ALL RIBS

-TRIMMED PIANO HINGE TO CORRECT LENGTH

Manual Reference: 7-11

FLAP BRACKETS

FABRICATED FL-706 BRACKETS

Manual Reference:

FIREWALL BRACKETS

WHILE I’M STUCK WAITING FOR PARTS I DECIDED TO MOVE ON TO SOMETHING TO KEEP ME WORKING.
-ROUGHLY CUT OUT F-601J ANGLES

-MARKED & FABRICATED F-601P SPACERS, F-601TD BRAKE PLATE & F601Z FUEL PUMP DOUBLER

-FINISHED 601J ANGLE CUTTING
-TIDIED UP ALL BRACKETS

Manual Reference: 8-1

STARTING FLAPS

-CLEANED UP LIGHTENING HOLE/EDGES ON FLAP SPARS
-DRILLED & CLECOED RIBS TO SPARS

-FABRICATED FL708 SHIMS
-THE RIBS WERE ALL CONTACTING THE REAR SPAR SO NO SHIMS WERE REQUIRED
-DRILLED RIBS TO REAR SPAR
-DRILLED RIBS TO BOTTOM SKIN
-MARKED 1/4″ LINE ON HINGES TO GET ALIGNMENT AND EDGE DISTANCE GOOD FOR DRILLING.

-CLAMPED AND DRILLED HINGES TO FLAP ASSY

-FITTED UPPER SKINS AND DRILLED FL-709 SHIMS TO ASSY
 

Manual Reference: 7-11

RH AILERON FINISHING

-COULDNT ACCESS THE TAIL TO RIVET THE FWD MOST LWR MAIN RIB RIVET SO REMOVED LWR BOLT OF BOTH BRACKETS, RIVETED & RETORQUED BOLTS
-POP RIVETED LWR SKIN-SPAR ROW 
-CHECKED STRAIGHTNESS AND IT CAME OUT GOOD
-RH AILERON IS NOW COMPLETE
BOTH AILERONS DONE!!

Manual Reference: 7-11

RH AILERON RIVETING

DUE TO MY FUEL TANK BAFFLE ISSUES I DECIDED TO GET INTO SOMETHING ELSE AND THOUGHT I’D GIVE THE RIGHT AILERON RIVETING A GO WITH SOME ASSISTANCE
-MADE SOME BRACKETS TO HOLD THE AILERON STEADY I SAW ON ANOTHER BUILDERS PAGE

-REMOVED 3 RIVETS FROM THE TOP AILERON SKIN ROW AND SUCESSFULLY INSTALLED ALL WITH MY BROTHERS ASSISTANCE
-RIVETED TOP HALF OF NOSE RIBS
-RIVETED TOP ROW OF MAIN RIBS & MAIN RIBS TO SPAR

-INSTALLED & TORQUED 407/407 BRACKETS
-FILLED A FEW TOOBOXES WITH BUCKING BARS & WEIGHTED DOWN AILERON TO KEEP FLAT

-POP RIVETED LEADING EDGE SKIN TO COUNTERBALANCE BAR
-RIVETED LEADING EDGE LWR RIBS
-RIVETED WHAT I COULD ON THE MAIN RIBS BUT HAVE TO SWAP OUT SQUEEZER HEADS AND AM OUT OF TIME

Manual Reference: 7-10, 7-11

STARTING RH FUEL TANK

-REMOVED VINYL FROM INSIDE OF FUEL TANK SKIN
-STARTED REMOVING VINYL FROM REAR TANK BAFFLE BUT UNDERESTIMATED THE STRENGTH OF THE ADHESIVE AND ENDED UP BUCKLING THE BAFFLE
-TRIED STRAIGHTENING THE REAR BAFFLE BUT NOT SATISFIED SO I’LL HAVE TO ORDER A NEW ONE
-STARTED FITTING RIBS INTO SKIN, DIDN’T WORK OUT AS EASY AS BEFORE, ENDED UP CLECOING TOP ROW, FITTING INTO CRADLE THEN TEMPORARILY FITTING THE REAR BAFFLE TO PUSH RIBS INTO PLACE WHILE I CLECO THEM.

-MARKED CENTRE LINES ON THE Z-BRACKETS & DRILLED CENTER HOLE
 

Manual Reference: DFD-21

RIGHT WING LEADING EDGE

-REMOVED VINYL FROM INSIDE RH LEADING EDGE

-MOUNTED IN CRADLE

-CLECOED RIBS IN PLACE (THOSE LOWER CLECOES WERE PAINFUL TO TRY AND LINE UP)

-MOUNTED ON MAIN SPAR AND CLECOED IN PLACE

-SLID IB RIB INTO PLACE AND BACKDRILLED TO SPAR
-MEASURED, MARKED AND FITTED W423 SPLICE PLATE
-LINED UP IB RIB AND SPLICE PLATE AND DRILLED/CLECOED IB RIB TO SKIN & SPLICE PLATE

-MATCH REAMED ALL RIBS TO SKIN
-EXTENDED TIEDOWN LINES & OPENED UP TO 7/16″

Manual Reference: 7-4, 7-5

BACK TO WORK, DRILLING RWING LWR SKINS

FINALLY GOT TIME TO GET BACK INTO THE RV WITH BEING STOOD DOWN FROM WORK
-CLEANED UP THE WORK AREA
-LUBED UP ALL AIR TOOLS
-CLEANED THE DUST OFF THE WING

-TOOK A BIT TO FIGURE OUT WHERE I’M AT
-IT LOOKS LIKE LAST TIME I WORKED I FITTED THE LWR RIGHT WING SKINS AND MATCH DRILLED MOST HOLES
-MOVED CLECOS OVER AND FINISHED MATCH DRILLING LWR MAIN SKINS
-TAPPED TIE DOWN ASSY
-FITTED TIE DOWN ASSY/ AILERON BELLCRANK BRACKETS WITH ALL 8 BOLTS AND TORQUED

-MARKED TIEDOWN LINES

-REMOVED LWR SKINS

Manual Reference: 7-2, 7-4

RIGHT WING MOUNTING BOTTOM SKINS

-CLECOED BOTTOM SKINS INTO PLACE

Manual Reference: 7-4

LEFT WING FLAP BRACE & AILERON GAP FAIRING

-COMPLETED MY WING STORAGE STAND AND MOVED THE LEFT WING INTO THAT

-MOVED MY RIGHT WING INTO THE CONSTRUCTION STAND

-RIVETED FLAP BRACE TO SPAR

-DRILLED, DEBURRED & DIMPLED THEN RIVETED AILERON GAP FAIRING TO SPAR AND TOP SKIN
***COULDN’T RIVET INBOARD-MOST AILERON GAP FAIRING RIVET DUE TO INTERFERENCE WITH NEW S.B AILERON MOUNT DOUBLERS, EMAILED VANS FOR ASSISTANCE***

Manual Reference: 7-9

LEFT WING AILERON BRACKETS/FLAP BRACE

-DRILLED OUTBOARD AILERON BRACKET TO SPAR/OB RIB
-TOUCHED UP TRIMMED INBOARD AILERON BRACKET WITH PRIMER
-I HAVE NOTICED THAT THE LWR RIVET ON BOTH THE BRACKETS IS A 426 (COUNTERSUNK) TYPE AND THE PLANS DON’T SEEM TO SHOW WHAT SIDE THE COUNTERSINK GOES ON, I’D IMAGINE IT ON THE AILERON SIDE FOR CLEARANCE BUT I’M GOING TO DO A BIT OF RESEARCH TO MAKE SURE I DON’T SCREW IT UP.
-AFTER A BIT OF RESEARCH FOUND THAT THE COUNTERSUNK RIVET IS INDEED ON THE AILERON SIDE TO GIVE CLEARANCE.
-REMOVED THE BRACKETS FROM THE SPAR AND COUNTERSUNK (THE CLEARANCE OF THE RIVET GOING THROUGH THE BRACKET MEANT THAT I HAD TO REMOVE THE COUNTERSINKING BIT FROM THE MICROSTOP AND COUNTERSINK IT BY HAND WITH THE DEBURRING HANDLE)

-ALODINED AND TOUCHED UP PRIMER ON BRACKETS
-WHILE WAITING FOR PRIMER ON BRACKETS TO DRY TRIED TO TRIAL FIT THE FLAP BRACE TO THE SPAR BUT FOUND IT REQUIRED TRIMMING.
–AFTER READING THROUGH PLANS FOUND A NOTE ON THE FLAP DRAWING (14A)
-TRIMMED & EDGE DEBURRED FLAP BRACE
-FITTED AND MATCH REAMED FLAP BRACE

-HOLE DEBURRED FLAP BRACE & TOUCHED UP TRIM AREA WITH ALODINE/PRIMER
-RIVETED AILERON BRACKETS IN POSITION ALONG WITH THE SB DOUBLERS

***INTENT OF S.B. 16-03-28 CARRIED OUT FOR THE LEFT WING IN THIS LOG ENTRY***

S.B. 16-03-28 MODIFICATIONS COMPLETED FOR LEFT WING, NO FURTHER ACTION NECESSARY FOR LEFT WING

Manual Reference: 7-9, S.B.16-03-28

LEFT WING TOP SKIN RIVETING

-FINISHED RIVETING LEFT WING TOP SKINS

-FITTED AILERON HINGES INTO POSITION, HAD TO SAND A BIT OF THE UPPER EDGE OF THE INBOARD HINGE BRACKET TO STOP IT FOWLING ON THE SKIN-SPAR RIVETS
-DRILLED INBOARD BRACKET TO SPAR AND ALODINED GROUND OFF AREA

Manual Reference: 7-9

RIGHT WING DRILLING TOP SKINS

-CLECOED TOP SKINS IN PLACE, FOUND THAT I HADN’T DRILLED SPAR CHANNEL TO SPAR REINFORCEMENT PLATES SO REMOVED THE OUTER SKIN DRILLED THOSE AND REATTACHED OUTER SKIN.

-DUE TO THE OTHER WING STILL BEING IN THE STAND THIS WING HAS TO BE WORKED ON THE BENCH WHICH MAKES MOST THINGS AWKWARD.
-DRILLED 1ST SET OF HOLES IN UPPER SKINS, NEED TO MOVE CLECOS AND DRILL THE REST BUT MY ARMS ARE TIRED FROM REACHING OVER THE WHOLE THING WITH A DRILL SO IT CAN WAIT FOR ANOTHER DAY

Manual Reference: 7-4

RIGHT WING PREPPING UPPER SKINS

-TEMP CLECOED UPPER SKINS IN PLACE AND MARKED SO AS TO AVOID MISTAKES & CONFUSION LATER

-DRILLED WINGWALK DOUBLER TO 702 UPPER IB SKIN

-CUT RIVET LINES OUT OF PROTECTIVE VINYL ON UPPER SKINS

Manual Reference: 7-4

RIGHT WING MAIN SPAR SKELETON RIVETING

-RIVETED REMAINING REAR SPAR-RIB RIVETS
-RIVETED ALL MAIN SPAR-RIB RIVETS

Manual Reference: 7-3

RIGHT WING REAR SPAR SKELETON RIVETING

-STARTED RIVETING RIGHT WING SKELETON TOGETHER

Manual Reference: 7-3

ALODINING/PRIMING RIGHT WING MAIN RIBS

-ALODINED MAIN RIBS
-PRIMED RIGHT WING MAIN RIBS

Manual Reference: 7-2

RH WING SKELETON DISSASSEMBLING/DEBURRING

-DISSASSEMBLED RH WING SKELETON
-DEBURRED BOTH SPARS
-DRILLED WIRING HOLE PILOTS IN RIBS USING TEMPLATE FROM LEFT WING
-DEBURRED BOTH RIBS
-OPENED UP WIRING HOLES TO 3/8

Manual Reference: 7-3

STARTING RH WING

-CLECOED MAIN SKELETON TOGETHER
-REAMED RIBS TO SPARS
-DISSASSEMBLED RH WING ASSY READY FOR DEBURRING/PRIMING

Manual Reference: 7-3

LH WING TOP SKIN RIVETING

-FINISHED RIVETING ONE MORE ROW OF RIB-SKIN RIVETS

Manual Reference: 7-9

RH AILERON CORROSION

-FOUND SOME LIGHT CORROSION ON THE RIGHT AILERON SO REMOVED IT AND PRIMED THE LOWER FWD SKIN AREA

Manual Reference:

RIVETING TOP SKIN LH WING

-RIVETED 2 MORE ROWS OF TOP SKIN LH WING

Manual Reference: 7-9

DEBURRING RIGHT WING RIBS

-ALREADY DEBURRED EDGES OF RIGHT WING RIBS WITH LEFT WING RIBS, SO ALL I HAD TO DO IS DEBURR THE RIGHT WING MAIN RIB LIGHTNING HOLES

Manual Reference: 7-3

LH WING LANDING LIGHT REWORK

***THE POSITION OF THE LANDING LIGHT HAS BEEN ANNOYING ME FOR A WHILE & INADVERTANTLY INSTALLED THE LENS UPSIDE DOWN SO IT DIDN’T FIT RIGHT SO WHILE I’M WAITING FOR AN EXTRA SET OF HANDS FOR RIVETING I DECIDED TO FIDDLE WITH IT.

-MODIFIED MOUNT BRACKET & REPAINTED
-PAINTED INSIDE OF LEADING EDGE AROUND LIGHT AREA
-REPAINTED BRACKET

Manual Reference:

ASSEMBLING AILERON ATTACH BRACKET ASSYS

-ASSEMBLED & RIVETED AILERON BRACKET ASSEMBLIES TOGETHER

Manual Reference: DWG10A

AILERON HINGE BRACKET DEBURRING/ PRIMING

-MATCH DRILLED AILERON HINGE BRACKET ASSYS
-COUNTERSUNK AILERON HINGE BRACKET ASSYS WHERE REQUIRED
-READ THROUGH SERVICE BULLETIN 16-03-28 (AFT SPAR CRACKING AT AILERON HINGE ATTACH)

-SEPARATED & EDGE DEBURRED SB PLATES
-ALUMIPREPPED & ALODINED SB PLATES AILERON HINGE BRACKET PIECES, FLAP BRACE & AILERON GAP FAIRING
-PRIMED SB PLATES AILERON HINGE BRACKET PIECES, FLAP BRACE & AILERON GAP FAIRING

Manual Reference: DWG10A, SB16-03-28

RIVETING LEFT WING OB TOP SKIN

-RIVETED 2 MORE BAYS OF UPPER SKIN

Manual Reference: 7-9

RIVETING LH TOP SKINS

-STARTED BY INSTALLING AFT 4 RIVETS IN LH AILERON TO COMPLETE IT.
-FOUND AND EDGE DEBURRED AILERON HINGE PLATES
-FINISHED RIVETING TOP IB SKIN ON EXCEPT OVERLAP WITH OB SKIN & STARTED RIVETING OB SKIN ON

Manual Reference: 7-9

COMPLETING LH AILERON

-COMPLETED UPPER/LWR SKIN TO TOP SPAR FLANGE RIVETING

-RIVETED UPPER NOSERIB-NOSE SKIN
-RIVETED TOP ROW OF AFT SKIN-MAIN RIB RIVETS
-INSTALLED ATTACH BRACKETS
-CLECOED & WEIGHED DOWN AILERON

-INSTALLED COUNTERBALANCE RIVETS
-INSTALLED LWR FWD/MAIN RIB RIVETS
-INSTALLED LWR SKINS-SPAR RIVETS
***LH AILERON COMPLETE EXCEPT AFT MOST 4 RIVETS WHICH I NEED A DIFFERENT SQUEEZER YOKE TO SET.

-INSTALLED AFT 4 RIVETS ON 29TH-NOV-16
***LH AILERON COMPLETE 

Manual Reference: 7-10/7-11

CONTINUING AILERON WORK

-REMOVED 2x RIVETS ON LH SPAR I ACCIDENTALY INSTALLED WHERE RIB GOES
-CLECOED & MATCH DRILLED NOSE RIBS TO SPARS

-CLECOED & MATCH DRILLED MAIN RIBS TO SPARS

***LH AILERON ONLY***
-CLECOED SKINS ON & MATCH DRILLED/OPENED IP LWR SPAR HOLES TO #30
-REMOVED TRAILING EDGE & DRILLED NOSE RIBS TO BALANCE WEIGHT

-DISSASSEMBLED, DEBURRED & DIMPLED LHS PARTS
-RIVETED NOSE RIBS TO WEIGHT
-RIVETED LE RIBS TO LE SKIN
-REALISED I WASN’T SUPPOSED TO RIVET LE RIBS TO SKIN YET, SO REMOVED 4 RIVETS FROM LE SKIN-RIB TO ALLOW RIVETING ACCESS
-RIVETED LE RIBS TO SPAR
-STARTED RIVETING LE/TE SKINS TO UPPER EDGE OF SPAR

 
Manual Reference: 7-10

AILERON WORK

-FOLDED TRAILING EDGES TO FINAL BEND
-CUT 408 REINFORCEMENT BRACKETS OUT OF SUPPLIED .040″ MATERIAL
-MATCH DRILLED REINFORCEMENT BRACKETS & AILERON ATTACH BRACKETS TO SPAR
-DEBURRED, COUNTERSUNK & PRIMED 408 REINFORCEMENT BRACKETS
-RIVETED 408 REINFORCEMENT BRACKETS TO SPARS & NUTPLATE TO LH ASSY ONLY AS I’M MISSING ONE OF MY NUTPPLATES.
***ACCIDENTALY INSTALLED 426 RIVETS IN LH IB SIDE WHERE IT SHOULD GO THROUGH MAIN RIB, SO I’LL HAVE TO REMOVE 2 OF THOSE LATER
***LEFT 1/8″ CLECOS AT HOME SO CAN’T PROGRESS ASSEMBLY ANY MORE

Manual Reference: 7-10

UPPER IB SKIN RIVETING

-RIVETED 2 MORE BAYS OF UPPER IB SKIN RIVETS WITH THE HELP OF MY BROTHER BRAEDEN

Manual Reference: 7-9

MORE AILERON PREP

-DEBURRED LE & MAIN AILERON RIBS
–LE RIBS WERE VERY FIDDLY, FOUND IT BEST TO USE A COMBINATION OF NEEDLE FILES, STRIPS OF SANDPAPER & SCOTCHBRITE
-PREPPED & PRIMED LE/MAIN RIBS & COUNTERBALANCE

Manual Reference: 7-10

AILERON PREP

-PREPPED, DEBURRED & PRIMED AILERON LE SKINS & SPARS

Manual Reference: 7-10

RIVETING UPPER SKINS

-TIDIED THE SHED UP A BIT
-DEBURRED FLAP & AILERON BRACES IN PREPARATION FOR USE
-RIVETED 2 RIBS ON THE IB UPPER SKIN

Manual Reference: 7-9

STARTING IB UPPER SKIN RIVETING

-FILED IB SKIN CORNER THAT IS OVERLAPPED BY THE OB SKIN
-STARTED RIVETING TOP IB SKIN ON, BUT BY MYSELF IT’S TOO AWKWARD 

 
Manual Reference: 7-9

LH AILERON STIFFENER RIVETING

-CLEANED & PRIMED AILERON SKIN
-RIVETED STIFFENERS TO SKIN

Manual Reference: 7-10

RH AILERON STIFFENER RIVETING

-CLEANED & PRIMED AILERON SKIN
-RIVETED STIFFENERS TO SKIN

Manual Reference: 7-10

PREPPING TO RIVET LEFT TOP SKINS

-PREPPED LH WING TO INSTALL TOP SKINS
-CLECOED IB TOP SKIN ON, BUT LEFT MY RIVET SETS AT WORK SO RIVETING WILL HAVE TO WAIT

Manual Reference: 7-9

FUEL TANK ATTACHING

-ROLLED FUEL TANK EDGES USING MY NEW EDGE ROLLER
-STRAPPED LEADING EDGE DOWN TO ALIGN HOLES BETTER

-BOLTED AND SCREWD LEADING EDGE DOWN, SAT MUCH BETTER, STILL A BIT OF PILLOWING BETWEEN SEAM SCREWS BU THIS IS AS GOOD AS I’LL GET IT

Manual Reference: 7-9

FUEL TANK REPAIR

-AFTER CONSULTING WITH VANS DECIDED TO STOP DRILL DAMAGED DIMPLES & THEY WILL BE PERIODICALLY INSPECTED AS PER DFD26
-SO STOP DRILLED 4x DAMAGED DIMPLES & MANUFACTURED DOUBLERS (DECIDED NOT TO USE DOUBLERS)

Manual Reference: DFD-0026

FUEL TANK ATTACH ISSUES

-REMOVED MORE EXCESS FUEL TANKS SEALANT AND INSTALLED ONTO SPAR
-STILL SAT PROUD ALONG THE SPAR SO REMOVED AND REMOVED EXCESS SEALANT SPANWISE
-WHILE DOING THIS FOUND THAT 3 INBOARD-MOST SCREW HOLES ON TANK WERE ELONGATED AND CRACKED

Manual Reference: 7-9

RIGHT WING ASSEMBLING REAR SPAR

-RIVETED REAR SPAR ASSY TOGETHER

Manual Reference: 7-2

FINISHING LEADING EDGE, STARTING TO FIT FUEL TANK

-FLIPPED WING OVER TO MAKE RIVETING EASIER
-RIVETED 3x INBOARD RIBS TO SPAR
-RIVETED THE LOWER SPANWISE ROW OF RIVETS 

-INSTALLED FUEL TANK ASSY & DECIDED TO INSTALL ALL SCREWS AND BOLTS INSTED OF THE HALF THE MANUAL CALLS OUT, I CAN’T SE WHY TO ONLY PUT HALF IN & ALL I CAN SEE THAT DOING IS CAUSING HOLE MISALIGNMENT ISSUES WHEN I TRY TO PUT ALL THE OTHERS IN.
-INSTALLED ALL SCREWS AND BOLTS LOOSELY, ONCE ALL WERE IN STARTED TO RUN SCREWS DOWN BUT DIDN’T LIKE BULGES I WAS GETTING BETWEEN SCREWS AT FUEL TANK SPLICE PLATE.
-REMOVED FUEL TANK AND MEASURED SPLICE & WHERE SEALANT ENDS ON TANK AND FOUND THAT THE SEALANT WAS INTERFERING WITH THE SPLICE PLATE
-REMOVED A SMALL AMOUNT OF EXCESS SEALANT FROM THE TANK & A SMALL AMOUNT OF MATERIAL FROM THE SPLICE PLATE
-HIT ALL BARE MATING SURFACES WITH THE ALODINE PEN
-REFITTED, STILL NOT HAPPY SO REMOVED AGAIN

Manual Reference: 7-9

RIVETING LEADING EDGE TO SPAR

-POP RIVETED OUTBOARD SINGLE RIVET & 2ND, 3RD RIB FROM OUTBOARD TO SPAR
-WAITING ON LP4-4 RIVETS SO CANT RIVET THE INBOARD 3x RIBS
-RIVETED TOP ROW OF LE SKIN-SPAR RIVETS

Manual Reference: 7-9, DFD-25

RHW REAR SPAR RIVETING/ AILERON SKIN DIMPLING

-RIVETED REINFORCEMENT FORK TOP ROW OF RIVETS BUT WAS UNHAPPY WITH THE FIT OF THE SQUEEZER CUP AGAIN, SO I’M GOING TO BUY YET ANOTHER CUP 

-RIVETED THE TIEDOWN ASSY TOGETHER

-DIMPLED BOTH AILERON SKINS
PICTURES- 1718-1722_x000D_

Manual Reference: 7-2

STARTING RIVETING LEADING EDGE TO MAIN SPAR

-STARTED RIVETING LEADING EDGE ASSY TO MAIN SPAR
–LWR TIP RIB CORNER OF LE RIB FLANGE BENT UP, MEANING I CAN’T GET A GOOD RIVET JOB SO I STOPPED FOR THE DAY

Manual Reference: 7-9

RIGHT WING REAR SPAR

-DRILLED/ DIMPLED UPPER REAR SPAR FLANGE HOLES WHERE THE REINFORCE FORK SITS
-CAN’T FIND MY #4 RIVET SET, SO HELD UP YET AGAIN BY MISSING TOOLS

Manual Reference: 7-2

Hours: 0.5

Total Hours: 380

PREPPING/PRIMING REAR SPAR

-DEBURRED REAR SPAR COMPONENTS
-ALUMIPREPPED & ALODINED REAR SPAR COMPONENTS & LEFT WING UPPER SKINS 
-PRIMED SPAR COMPONENTS & LEFT WING UPPER SKINS

Manual Reference: 7-2

RHW TIEDOWN ASSY & REAR SPAR PREP

-CUT TIEDOWN SPACERS OUT OF SUPPLIED BAR-DRILLED LIGHTNING HOLE OUT OF SPACERS

-MEASURED AND DRILLED REFERENCE POINT ON 731 TIEDOWN BAR
-CLAMPED SPACERS AND TIEDOWN BAR TO SPAR AND DRILLED ATTACH HOLES
-DRILLED COUNTERSUNK ASSY FOR PLATENUTS

-PREPPED SPACERS & TIEDOWN BAR FOR PRIMING

REAR SPAR
-FOUND SOME LIGHT CORROSION ON THE REAR SPAR CHANNEL WHEN I REMOVED THE VINYL.
-CORROSION REMOVED REFER DFD23

-MARKED & TRIMMED 707D & G AS PER DWG 38

-EDGE DEBURRED SPAR, REINFORCEMENT FORK & REINFORCEMENT PLATES
-MATCH DRILLED DOUBLER PLATES TO SPAR

-CUT OUT AILERON PUSHROD HOLE IN DOUBLER

-INSTALLED AND MATCH DRILLED REINFORCEMENT FORK AND PLATE

Manual Reference: 7-2

RH WING SPAR NUTPLATES

-DIMPLED WING ACCESS PANELS SPAR ROW
-COUNTERSUNK SPAR TO FIT ACCESS PANELS

-TOUCHED UP ALL COUNTERSINKS WITH ALODINE PEN
-ATTACHED CENTRE SECTION NUTPLATES TO THE SPAR

Manual Reference: 7-2

STARTING RIGHT WING

-GAVE THE SHED A TIDY UP
-STILL CAN’T FIND MY OFFSET RIVET SET TO FINISH MY LEFT WING SO I DECIDED TO START ON MY RIGHT WING.
-FIRSTLY I SLID THE LEFT WING INTO THE BACK OF THE STAND AND TEMPORARILY MODIFIED THE ARMS TO HOLD THE RIGHT SPAR AS WELL.

-DRILLED, DEBURRED AND RIVETED TANK ATTACH PLATENUTS TO SPAR
-DRILLED, DEBURRED AND RIVETED ACCESS PANEL PLATENUTS TO SPAR
-COUNTERSUNK TANK ATTACH SCREW HOLES

Manual Reference: 7-2, 7-2

PREPARING TO FINISH LEFT WING

-FITTED LEADING EDGE ASSY TO SPAR AND CLECOED ON
-CLEANED UP FUEL TANK MATING SURFACES & DIMPLED SCREW HOLES FOR #8 SCREW
-TRIAL FITTED FUEL TANK TO SPAR
-TORE MY SHED APART TRYING TO FIN MY OFFSET RIVET SET WITHOUT LUCK
-DIMPLED OUTBOARD UPPER SKIN

Manual Reference: DWG16A, 7-9

LANDING LIGHT

-DRILLED LENS TO SKIN

-DRILLED LENS-SKIN TO #30
-DRILLED LENS TO 5/32 AND COUNTERSUNK
-PREPPED REATINING STRIPS & RIVETED NUTPLATES ON

-INSTALLED LAMP ASSY INTO BRACKET
-TRIED TO INSTALL LENS BUT REALIZED I’D INADVERTANTLY FITTED A LARGE NUTPLATE ON RETAINING STRIPS, SO REMOVED NUTPLATE AND INSTALLED THE CORRECT ONE
-FINALLY INSTALLED LENS

***LANDING LIGHT INSTALLATION COMPLETE, EXCEPT WIRING AND MOISTURE BARRIER TAPE, WILL INSTALL THAT ONCE LIGHTS ARE ADJUSTED

Manual Reference: MOD005

LANDING LIGHT WORK

-FINAL TORQUED TIEDOWN ASSY TO SPAR
-TIDIED UP LANDING LIGHT CUTOUT

-FABRICATED 2x RETAINER STRIPS TO SUIT LARGER CUTOUT

-MATCH DRILLED RETAINER STRIPS TO LEADING EDGE
-MATCH DRILLED NUTPLATE HOLES FROM OLD RETAINER STRIPS TO NEW ONES

-MARKED/DRILLED HOLES IN RIBS USING TEMPLATE (CORRECTLY THIS TIME!!)
-CLECOED NUTPLATES TO RIBS AND MATCH DRILLED

-POP RIVETED NUTPLATES TO RIBS
-INSTALLED LIGHT MOUNT BRACKET IN LEADING EDGE

-TRIMMED PLEXI LENS

Manual Reference: MOD005

EXTENDING LANDING LIGHT HOLE

-AFTER CONSULTING OTHER BUILDERS I DECIDED TO EXTEND THE LANDING LIGHT CUTOUT 1.5″ OUTBOARD SO THE LED LAMPS WOULD LINE UP, THIS WILL ALSO GIVE THE BENEFIT OF BETTER LIGHT DISPURSION INBOARD.
-MARKED AND ROUGHLY CUT OUT THE EXTENDED HOLE BUT DIDN’T HAVE MY ROTARY BURR HERE TO TIDY IT UP

Manual Reference: MOD005

CUTTING LANDING LIGHT HOLE

-CUT OUT AND LAID TEMPLATE OVER LEADING EDGE

-MARKED CUT OUT LINES

-CUT OUT ROUGH LANDING LIGHT HOLE IN THE LEADING EDGE
-FOUND IT REALLY EASY TO CUT WITH THE DREMEL CUT-OFF WHEEL & ROTARY BURR

***FOUND THAT I’D FITTED THE TEMPLATE UPSIDE DOWN WHEN I MARKED SO THE CUTOUT WAS 1.5″ INBOARD OF WHERE IT WAS SUPPOSED TO BE

Manual Reference: MOD005

LANDING LIGHTS ARRIVAL

MY LANDING LIGHTS ARRIVED TODAY FROM DUCKWORKS, I ORDERED THE LED LIGHTS .
-I STARTED BY PRIMING AND PAINTING THE LIGHT MOUNT BRACKET BLACK TO MATCH THE LIGHT AS THIS WILL BE CLOSED UP SOON AND I DONT WANT IT TO LOOK OUT

Manual Reference: MOD005

PRIMING LH AILERON STIFFENERS

-CLEANED, DIMPLED & PRIMED AILERON STIFFENERS

PRIMING RH AILERON STIFFENERS

-CLEANED, DIMPLED & PRIMED AILERON STIFFENERS

Manual Reference:

IB SKIN DIMPLING

DIMPLED BOTH INBOARD SKINS

Manual Reference:

LH AILERON DRILLING SKINS

-FIGURED OUT WHICH WAY WAS UP & DOWN & MARKED SKIN & SPAR
-MATCH DRILLED STIFFENERS TO SKIN
-DEBURRED SKINS
-DEBURRED STIFFENERS

Manual Reference: 7-10

RH AILERON DRILLING SKINS

-FIGURED OUT WHICH WAY WAS UP & DOWN & MARKED SKIN & SPAR
-MATCH DRILLED STIFFENERS TO SKIN
-DEBURRED SKINS
-DEBURRED STIFFENERS

Manual Reference: 7-10

DIMPLER HANDLE

-HAD CLEARANCE ISSUES WITH HANDLE HITTING LARGE ALUMINIUM SHEETS ON MY DIMPLER SO I MADE A NEW HANDLE WHICH SHOULD STOP THIS ISSUE

Manual Reference:

Hours: 1

Total Hours: 357

COUNTERSINKING SPAR

-COUNTERSUNK ALL HOLES ON MAIN SPAR

-TRIED TO “TOUCH UP” REAR SPAR DIMPLES WITH COUNTERSINKER BUT THE DIMPLES SEEM TO BE DEEP ENOUGH ALREADY
-TOUCHED UP ALL COUNTERSINKS WITH ALODINE PEN.

-FOUND THAT THE JACK THAT WAS KEEPING THE WING FROM SAGGING IN THE CENTRE KEEPS SLOWLY DROPPING, SO I MADE A SMALL STAND TO KEEP THE WING LEVEL

Manual Reference: 7-8/7-9

DEBURRING/DIMPLING WING SKELETON

-DEBURRED REAR SPAR
-DEBURRED MAIN SPAR
-DIMPLED RIBS
-DIMPLED REAR SPAR 
*ALL THAT REMAINS IS COUNTERSINKING OF SPARS AND SKIN EDGE DEBURRING
*I’VE ORDERED MY DUCKWORKS LED LANDING LIGHTS AS WELL SO I’LL HAVE TO WAIT TILL THEY COME BEFORE I RIVET MY LEADING EDGE TO THE SPAR

Manual Reference: 7-8

DEBURRING WING RIBS

-HOLE DEBURRED WING RIBS

LEFT AILERON STIFFENERS

*STARTED WORKING ON THE AILERONS AT WORK IN MY FREE TIME
-TRIMMED AILERON STIFFENERS
-TIDIED UP & EDGE DEBURRED STIFFENERS

Manual Reference: 7-10

Hours: 1.5

Total Hours: 348.5

RIGHT AILERON STIFFENERS

*STARTED WORKING ON THE AILERONS AT WORK IN MY FREE TIME
-TRIMMED AILERON STIFFENERS
-TIDIED UP & EDGE DEBURRED STIFFENERS

Manual Reference: 7-10

Hours: 1.5

Total Hours: 350

RIVETING LEADING EDGE

-RIVETED ALL REMAINING LEADING EDGE RIVETS

LEADING EDGE ASSY RIVETING

-RIVETED AFT 2 RIVETS ON ALL LE RIBS
-RIVETED #1 RIB IN

Manual Reference: 7-9

HOLE DEBURRING MAIN WING SKINS/STARTING SKELETON

-FINISHED HOLE DEBURRING SKINS
-HOLE DEBURRED UPPER FACING HOLES ON SKELETON
-RIVETED NUTPLATES ONTO 423 SPLICE PLATE

Manual Reference: 7-8, 7-9

LE PRIMING, MAIN SKIN DEBURRING

-DEBURRED & DIMPLED WINGWALK DOUBLER SKIN
-ALUMIPREPPED/ ALODINED & PRIMED LE RIBS, WINGWALK DOUBLER & 423 SPLICE PLATE

-HOLE DEBURRED BOTH INBOARD SKINS, STARTED HOLE DEBURRING LWR OUTBOARD SKIN

Manual Reference: 7-8

CONTINUED LE WING DEBURRING

-HOLE DEBURRED LE RIBS
-REMOVED EXTERIOR PLASTIC FROM LEADING EDGE SKIN
-FINISHED HOLE/ EDGE DEBURRING LE SKIN
-DIMPLED LE SKIN
-DIMPLED LE RIBS

-DIMPLED 423 SPLICE PLATE, DRILLED FOR NUTPLATES & DIMPLED

-PRIMED LE SKIN INTERNALS

-LEFT OUT PREPPING & PRIMING RIBS AND SPLICE PLATE UNTIL WEATHER IMPROVES

DEBURRING LE SKIN

-INSTALLED IB LWR FUEL TANK ATTACH PLATENUT USING BLIND RIVETS, SEE DFD22
-HOLE & EDGE DEBURRED FUEL TANK-LEADING EDGE SPLICE PLATE
-HOLE DEBURRED INSIDE AND LWR HALF OF EXTERIOR LE SKIN

RIVETING STALL WARNING ACCESS HATCH DOUBLER

-RIVETED NUTPLATES ONTO STALL WARNING ACCESS HATCH DOUBLER
-RIVETED ACCESS HATCH DOUBLER TO LEADING EDGE SKIN

DECIDED NOT TO INSTALL STALL WARNING SYSTEM AS I’M INSTALLING AN ANGLE OF ATTACK SYSTEM WHICH WILL WARN OF IMPENDING STALL.

WIRING HOLES/STALL WARNING

MOST OF TODAY WAS SPENT GETTING MY HEAD AROUND WHERE I WAS UP TO BEFORE THE 6 MONTH BREAK
-DIMPLED #6 SCREW HOLES IN W822PP ACCESS PANELS THAT I’D SKIPPED EARLIER (REF 7-2 PARA 2)
-FITTED AOA BUSHINGS AND RUN AOA & PITOT LINES THROUGH WINGS

DECIDED TO RUN WIRES IN A 1/4″ BUSHING DRILLED IN THE LOWER 1/3 OF THE RIB BETWEEN THE LARGE LIGHTENING HOLE AND THE NEXT ONE AFT.
-FABRICATED DRILL TEMPLATE FOR WIRING PILOT HOLES
-DRILLED #30 WIRING PILOT HOLES

-OPENED ALL HOLES UP TO 3/8″ AND INSTALLED BUSHINGS FOR WIRING, 1/4″ ID BUSHING SHOULD BE PLENTY, IF NOT I CAN GET BIGGER LATER.

STALL WARNING 
-FINAL DRILLED MAIN SPAR FOR WIRING RUN AND INSTALLED SB375-3 BUSHING
– CLECOED & DRILLED ACCESS HATCH DOUBLER TO LE SKIN
-FINAL DRILLED NUTPLATE ATTACH HOLES ON ACCESS HATCH DOUBLER
-DEBURRED ALL HOLES AND EDGES ON HATCH, DOUBLER AND LE SKIN-HATCH ATTACH HOLES
-DIMPLED #6 SCREW HOLES
-DIMPLED DOUBLER-SKIN RIVET HOLES
-DIMPLED NUTPLATE HOLES ON DOUBLER & PRIMED WITH SPRAY CAN PRIMER
-DIMPLED NUTPLATES
 

PITOT STATIC PLUMBING HOLES

FINALLY BACK IN THE SHED AFTER A FEW MONTHS OFF
-STARTED BY MAKING UP A LONG DRILL TO DRILL PITOT/AOA HOLES THROUGH THE WING WALK RIBS, AFTER A LOT OF THINKING I ENDED UP JUST WELDING A PIECE OF STEEL BAR ONTO THE 3/8 DRILL BIT, AND THIS WORKED WELL

-DRILLED AOA HOLES IN WINGWALK RIBS READY FOR BUSHINGS TO BE FITTED
-ORDERED REQUIRED HARDWARE FROM VANS

Manual Reference:

CLOSING LH FUEL TANK

-CLEANED UP ALL PARTS WITH MEK
-CARRIED OUT CONTINUITY CHECK OF CAPACITIVE SENDER PLATES/PLUG
-CARRIED OUT FINAL CLEARANCE CHECK ON FUEL TANK BAYS
-TOOK VIDEO OF CLEARANCE CHECK – SEE VIDEO 20150420_154440_

-SEALED TERMINALS ON IB SENDER PLATE
-RUN SEALANT ALONG BAFFLE RIVET LINES ON TANK ASSY
-RUN SEALANT ALONG RIB AFT FLANGES – EXTRA SEALANT ON END RIB CORNERS
-INSTALLED T-702 BAFFLE INTO PLACE WITH A CLECO IN EVERY SKIN-BAFFLE HOLE
-RIVETED ALL RIB TOP AND BOTTOM HOLES WITH POP RIVETS IN ALL BUT END RIBS & SOLIDS IN THE END RIBS
-INSTALLED ALL T-712 Z-BRACKETS USING POP RIVETS IN CENTRE RIBS AND SOLIDS IN END RIBS
*HAD TO GRIND A FAIR BIT OFF MY POP RIVET GUN TO FIT IT ON THE Z-BARCKETS
-RIVETED ALL LENGTHWISE SKIN-BAFFLE RIVETS WITH 3.5 SOLID RIVETS

-RUN SEALANT AROUND T-708 COVER PLATE & INSTALLED ONTO TANK

AS USUAL I MADE A HELL OF A MESS BUT IT SHOULDN’T LEAK

EXCEPT FOR CLEANING UP FUEL TANK IS COMPLETE, IM GLAD THATS OVER!!

         
PICTURES- 1623-1642
RIVETS – INST 183 – REM 0
WING RIVETS – INST 751 – REM 25
TOTAL PROJECT RIVETS – INST 3072 – REM 78

Manual Reference: 7-7, 7-8

PREPARING TO CLOSE LH TANK

-TIDIED UP SURFACES TO BE SEALED WITH REAR BAFFLE
-CLEANED ALL LOOSE ITEMS OUT OF TANK
-GOT ALL PARTS READY TO CLOSE TANK

SEALING & RIVETING IB END RIB INTO PLACE

-SEALED & RIVETED IB END RIB INTO PLACE
-SEALED AND RIVETED T-405 & T-410 INTO PLACE
 

-RUN SEALANT AROUND T-407 RING

Manual Reference: 7-7

SEALING AND RIVETING OB END RIB INTO TANK

-INSTALLED IB CAPACITIVE FUEL PLATE 

-TRIAL FITTED VENT LINE, BENT IB END AS REQUIRED & CHOPPED OB END TO FIT CORRECTLY

-FABRICATED PLATE TO COVER TOOLING HOLE ON END OF OB RIB
-SEALED & RIVETED TOOLING HOLE COVER ONTO RIB & T410

*FOUND THAT RIVETING THE 410 ONTO THE RIB BOWED THE RIB MAKING IT VERY DIFFICULT TO RIVET INTO PLACE
-SEALED VENT LINE INTO CLIP WITH FUEL TANK SEALANT

-CLECOED OB END RIB INTO PLACE WITH EXTREME DIFFICULTY
-RIVETED OB END RIB INTO PLACE AND CLEANED UP
MADE A HUGE MESS BUT HOPEFULLY IT’LL SEAL OK

Manual Reference: 7-7, OP-7

RIVETING RIB #6 INTO POSITION

-CLEANED UP ALL HOLES/COUNTERSINKS
-USED TOOTHPICK WITH SEALANT UNDER THE RIVET HEADS TO INSTALL RIVETS WET
-RIVETED RIB #6 INTO PLACE
-MID WAY THROUGH COMPRESSOR STOPPED WORKING, SO BORROWED ANOTHER COMPRESSOR BUT DIDNT GET A CHANCE TO GET PICS
-SEALED SHOP HEADS

Manual Reference: 7-6, 7-7

SEALING RIB 6 INTO POSITION

SEALED RIB # 6 INTO POSTION READY TO BE RIVETED

Manual Reference: 7-6, 7-7

LEFT FUEL TANK VENT LINE

-FLARED LH FUEL TANK VENT LINE
-CRIMPED ALL REMAINING CAP FUEL SENSOR FITTINGS

Manual Reference: 7-6, 7-7, 7-8 OP-7

RIVETING RIBS 3, 4 & 5

-CLEANED UP ALL HOLES/COUNTERSINKS
-USED TOOTHPICK WITH SEALANT UNDER THE RIVET HEADS TO INSTALL RIVETS WET
-RIVETED RIBS 3, 4 & 5 INTO PLACE
-SEALED SHOP HEADS
-DONE FOR TODAY

Manual Reference: 7-6, 7-7

SEALING RIBS 3, 4 & 5 INTO PLACE

-DECIDED TO TRY A LESS MEESY WAY TO SEAL RIBS IN, WHERE THEY ARE SEALED IN PLACE WITH ALL CLECOES THEN RIVETED THE NEXT DAY.
-SEALED RIBS 3, 4 & 5 INTO PLACE WITH ALL CLECOES 
 

Manual Reference: 7-6, 7-7

SEALING/RIVETING RIB 2 INTO PLACE

-SCREWED OB CAPACITIVE PLATE TO RIB #6 & BOLTED WIRE TO IT

-CLEANED UP SKIN WHERE RIBS WILL BE SEALED
-SEALED & RIVETED 1ST RIB INTO SKIN, COULDN’T DO ANYMORE AS THE SEALANT WAS GOING OFF

Manual Reference: 7-6, 7-7, OP-7

SEALING FUEL TANK PARTS

-INSTALLED AND SEALED CAPACITIVE FUEL SENDER PLUG TO IB RIB

-RIVETED & SEALED FUEL CAP TO SKIN

-ATTACHED/SEALED ALL FUEL PICKUP HARDWARE TO ACCESS PANEL

Manual Reference: 7-6

RIVETS – INST 12 – REM 0
WING RIVETS – INST 555 – REM 30
TOTAL PROJECT RIVETS – INST 2770 – REM 77

Hours: 3

Total Hours: 303.75

PREPPING LH WING SKINS

-Removed vinyl from rivet holes on skin
-Deburred 1 wing skin

Manual Reference:

Hours: 2

Total Hours: 300.75

FUEL TANK - RIVETING STIFFENERS

-Started by scuffing up the rivet lines

-Cleaned up all parts with MEK
-Decided to use PPG PR1440-B2 Sealant
-Started riveting stiffeners to skin, making a hell of a mess but its well covered

-Riveted all stiffeners to skin covering the shop head with sealant and the stiffeners under the filler cap covered by more sealant as it will be subjected to fuel flow from the filler nozzle
-Installed drain flange & had to remove it due to unsatifactory rivets
-Cleaned up drain flange area and re-riveted, made a big mess due to the sealant starting to go off
-Will scrape off excess sealant later using a nylon scraper

Manual Reference:

RIVETS – INST 84 – REM 6
WING RIVETS – INST 543 – REM 30
TOTAL PROJECT RIVETS – INST 2758 – REM 77

Hours: 1

Total Hours: 298.75

DIMPLING FUEL TANK

-Pilot drilled capacitive fuel sensor plug & fuel vent line holes in inboard rib

-Dimpled stiffeners
-Dimpled ribs
-Dimpled rivet holes on skin
-Deburred Screw holes on fuel tank skin

Manual Reference:

RIVETS – INST 0 – REM 0
WING RIVETS – INST 459 – REM 24
TOTAL PROJECT RIVETS – INST 2674 – REM 71

Hours: 2

Total Hours: 297.75

FUEL TANK DEBURRING

-Deburred ribs, baffle & stiffeners
-Marked drill holes for capacitive fuel sensor plug & fuel vent line in inboard rib

-Cut and straightened fuel vent line
-Cut capacitive fuel sensor wires to length
-Soldiered fuel sensor short wire to bulkhead plug

Manual Reference:

RIVETS – INST 0 – REM 0
WING RIVETS – INST 459 – REM 24
TOTAL PROJECT RIVETS – INST 2674 – REM 71

Hours: 2

Total Hours: 295.75

FUEL TANK CAPACITIVE FUEL SENDER

-Drilled Capacitive fuel plate to OB rib #20

-Opened rib holes up to 1/4″
-Trimmed stiffeners & plate to give required clearance
-Drilled Capacitive fuel plate to IB rib #20
-Opened rib holes up to 1/4″

-Riveted nutplates to Capacitive Plates
-Modified snap bushings to fit both capacitive fuel sensor wire and 1/4″ fuel tube.

Manual Reference:

RIVETS – INST 12 – REM 0
WING RIVETS – INST 459 – REM 24
TOTAL PROJECT RIVETS – INST 2674 – REM 71

Hours: 2

Total Hours: 293.75

FUEL TANK STIFFENERS

-Drilled fuel tank assembly
-Drilled Fuel pickup holes to 411 panel
-Cut out 711 stiffeners which I hadn’t done previously
-Tidied up stiffeners
-Drilled Stiffeners to to skin

-Countersunk Fuel Tank skin only on baffle row of ribs

-Drilled spar attach screw holes to #19
-Fabricated T405 attach angle, I didn’t have a bandsaw or similar so I had to make do with a hacksaw, linishing belt & scotchbrite wheel

-Deburred T410 plates
-Drilled 405 plates roughly as shown in plans
-Clamped 405 & 410 Reinforcement plates on end ribs & drilled

-Drilled & Clecoed VA112 drain flange to tank, used rod end bearing to align hole in tank skin.

-Have to skip over fitting the cap assembly as I ordered the delux cap and am still waiting for it to arrive.

Manual Reference:

RIVETS – INST 0 – REM 0
WING RIVETS – INST 447 – REM 24
TOTAL PROJECT RIVETS – INST 2662 – REM 71

Hours: 6.5

Total Hours: 291.75

FUEL TANK ACCESS PANEL WORK

-AFTER CONSULTATION WITH THE SHEETMETAL GUYS AT WORK I DECIDED RATHER THAN CUT THE 703 FUEL TANK RIB ACCESS HOLE WITH A FLY CUTTER I’D JUST CHAIN DRILL AND CUT OUT.
-SO I CHAIN DRILLED AND CUT OUT THE 703 RIB ACCESS HOLE AND TIDIED IT UP

-I DRILLED THE UNCUT T411 ACCESS PANEL TO THE RIB, THEN CLECOED THE REINFORCEMENT RING & DRILLED NUTPLATE HOLES IN THE RIB

-NEXT I DEBURRED/COUNTERSUNK AND DIMPLED THE HOLES, THEN FORGETING TO ATTACH NUTPLATES STARTED RIVETING THE RING TO THE RIB

-AFTER 16 RIVETS REALIZED THAT I HAD MISSED THE NUTPLATES AND REMOVED THEM ALL AND RE RIVETED WITH THE NUTPLATES

Manual Reference:

RIVETS – INST 40 – REM 16
WING RIVETS – INST 447 – REM 24
TOTAL PROJECT RIVETS – INST 2662 – REM 71

Hours: 4

Total Hours: 285.25

FUEL TANK WORK

-DRILLED 1/8″ HOLE IN ALL 712 ANGLES
-TRIED TO BOLT ANGLES TO THE SPAR BUT HAD SOME ISSUES WITH THE PLATENUTS LINING UP SO DECIDED TO CALL IT AND HAVE A BEER

Manual Reference: 7-5

RIVETS – INST 0 – REM 0
WING RIVETS – INST 362 – REM 6
TOTAL PROJECT RIVETS – INST 2577 – REM 5

Hours: 1

Total Hours: 273.75

FUEL TANK FITTING

-BOLTED 3 ATTACH “Z” BRACKETS TO SPAR – NOT ROOT BRACKET AS I NEED A VERY THIN WALLED SOCKET TO DO UP BOLTS.
-CLECOS ARRIVED SO CLECOED FUEL TANK TOGETHER FULLY

Manual Reference:

RIVETS – INST 0 – REM 0
WING RIVETS – INST 407 – REM 8
TOTAL PROJECT RIVETS – INST 2622 – REM 55

Hours: 2

Total Hours: 279.25

FUEL TANK SPAR NUTPLATES

-RIVETED 2 OF THE FUEL TANK ROOT NUTPLATES TO THE MAIN SPAR
–COULDN’T GET ACCESS FOR THE LAST NUTPLATE SO DECIDED TO POP RIVET THE LAST ONE ON
-BOLTED 3 OF THE Z BRACKETS TO THE SPAR

Manual Reference:

RIVETS – INST 4 – REM 0
WING RIVETS – INST 407 – REM 8
TOTAL PROJECT RIVETS – INST 2622 – REM 55

Hours: 1

Total Hours: 277.25

RESTARTING FUEL TANK - ALTERNATIVE METHOD

AFTER HAVING ISSUES WITH ATTACHING THE FUEL TANK “Z” BRACKETS TO THE SPAR I DECIDED TO FOLLOW THE RECOMMENDED “CHECKOWAY” OR “ALTERNATIVE” METHOD, I SCRAPPED MY OLD Z BRACKETS ORDERED MORE AND STARTED.
-STARTED BY ASSEMBLING THE FUEL TANK ASSY WITH CLECOES, I DIDN’T HAVE ANY ISSUES WITH THIS, I FOUND THE EASIEST WAY WAS TO CLECO THE TOP ROW OF THE SKIN TO THE RIBS THEN PUSH THE ASSY TIGHTLY INTO THE STAND AND THE HOLES WERE PRETTY CLOSE TO LINING UP, THEY ONLY NEEDED A BIT OF A PUSH TO LINE UP AND CLECO
-MARKED THE CENTRELINES ON THE Z BRACKETS AND DRILLED THE CENTREMOST 3/16″ HOLE, I READ AROUND AND DIDN’T BOTHER OFSETTING THE LINES AS SOME HAD SUGGESTED.
-BOLTED BRACKETS TO THE SPAR, BACK DRILLED THE NEXT HOLE, PUT A BOLT THROUGH THE SECOND HOLE AND DRILLED THE LAST HOLE
-NEXT I NUMBERED AND REMOVED ALL THE BRACKETS, AND DEBURRED, DRILLED AND RIVETED PLATENUTS TO ALL BUT THE ROOT BRACKET, AND STARTED TO RIVET THE ROOT PLATENUTS TO THE SPAR

Manual Reference: DFD-0021

RIVETS – INST 41 – REM 2
WING RIVETS – INST 403 – REM 8
TOTAL PROJECT RIVETS – INST 2618 – REM 55

Hours: 2.5

Total Hours: 276.25

LH WING DRILLING LEADING EDGE

-DRILLED AND TAPPED PITOT TUBE/MAST

-MATCH REAMED LEADING EDGE ASSY.
-ENLARGED TIEDOWN HOLE IN SKIN TO 7/16″, THE HOLE ENDED UP NICE AND CENTRAL ON THE TIEDOWN ASSY

-SUMMER’S STARTING TO HIT SO ITS GETTING HARD TO SPEND EXTENDED PERIODS OF TIME IN THE SHED WITH IT BEING OVER 40 DEGREES C (104 DEGREES F) INSIDE

Manual Reference: 7-5

RIVETS – INST 0 – REM 0
WING RIVETS – INST 326 – REM 6
TOTAL PROJECT RIVETS – INST 2541 – REM 53

Hours: 1.5

Total Hours: 270.25

STARTING FUEL TANK

-MARKED VERTICAL CENTRELINE ON T-712 TANK ATTACH ANGLES
-MARKED LENGTHWAYS CENTRE
-DRILLED 6x 712 CENTRE FLANGES TO #12
-CLECOED ANGLES TO REAR OF SPAR

-MATCH DRILLED REMAINING TANK ATTACH HOLES TO ANGLE
-FABRICATED NUTPLATE JIG
-DRILLED NUTPLATE HOLES TO 712 ANGLES
-COUNTERSUNK ANGLE & RIVETED NUTPLATES TO ANGLE

Manual Reference: 7-5

RIVETS – INST 36 – REM 0
WING RIVETS – INST 362 – REM 6
TOTAL PROJECT RIVETS – INST 2577 – REM 5

Hours: 2.5

Total Hours: 272.75

LH WING LEADING EDGE WORK

-CLECOED LEADING EDGE ASSY TO SPAR
-DIMPLED UNDRILLED W-408 RIB AND SLID INTO PLACE ON THE IB END OF THE ASSY
-DRILLED REAR FLANGE THROUGH SPAR
-SLID TANK JOINT PLATE IN BETWEEN RIB AND SKIN AND DRILLED.

Manual Reference: 7-4, 7-5

RIVETS – INST 0 – REM 0
WING RIVETS – INST 326 – REM 6
TOTAL PROJECT RIVETS – INST 2541 – REM 53

Hours: 1

Total Hours: 268.75

LH WING SKIN DRILLING

-MATCH REAMED TOP SKINS TO SKELETON
-MATCH REAMED BOTTOM SKINS TO SKELETON
-DREW TIE DOWN LINES ON LOWER SKIN
-REMOVED BOTTOM SKINS
-REMOVED VINYL FROM INSIDE OF W-701 LEADING EDGE SKIN
-CLECOED LEADING EDGE ASSY TOGETHER

-SAT LEADING EDGE ON SPAR

Manual Reference: 7-4, 7-5

RIVETS – INST 0 – REM 0
WING RIVETS – INST 326 – REM 6
TOTAL PROJECT RIVETS – INST 2541 – REM 53

Hours: 3

Total Hours: 267.75

LEADING EDGE CRADLE

-ASSEMBLED THE LEADING EDGE CRADLE AS PER THE MANUAL

Manual Reference:

RIVETS – INST 0 – REM 0
WING RIVETS – INST 326 – REM 6
TOTAL PROJECT RIVETS – INST 2541 – REM 53

Hours: 1

Total Hours: 264.75

LH WING FITTING UPPER SKIN

-CUT BOTH WING WALK DOUBLERS TO SIZE
-DRILLED SKIN TO DOUBLER

-SECURED MAIN SPAR INTO STAND
-TAPPED TIE DOWN ASSY
-FITTED TIE DOWN ASSY/ AILERON BELLCRANK BRACKETS WITH CENTER FOUR BOLTS AND TORQUED
-FITTED UPPER SKINS TO SKELETON (NOTE: I DECIDED NOT TO DO SINGLE PIECE UPPER WING SKINS WHEN I RANG OUR LOCAL ALUMINIUM SUPPLIER AND WAS QUOTED $380 PER SHEET)

Manual Reference: 7-4

RIVETS – INST 0 – REM 0
WING RIVETS – INST 326 – REM 6
TOTAL PROJECT RIVETS – INST 2541 – REM 53

Hours: 3

Total Hours: 263.75

FITTING PITOT MAST

-FITTED MY SAFEAIR1 PITOT MAST TO THE LOWER SKIN AS PER INSTRUCTION,
THE TEMPLATE MOVED AND MY CUTOUT DIDN’T COME OUT AS NICE AS IT COULD BUT IT’S ACCEPTABLE AND IT’LL JUST NEED A TIDY UP LATER TO COSMETICALLY MAKE IT LOOK NICE.
-ALSO THE FWD AREA OF THE BRACKET NEEDS A TRIM SO AS NOT TO INTERFERE WITH FWD SKIN RIVETS.

Manual Reference:

RIVETS – INST 0 – REM 0
WING RIVETS – INST 326 – REM 6
TOTAL PROJECT RIVETS – INST 2541 – REM 53

Hours: 1

Total Hours: 260.75

LH WING RIVETING RIBS-MAIN SPAR

-FINISHED RIVETING MAIN RIBS TO FWD SPAR

-SKIPPED FITTING TOP SKINS FOR NOW AS I AM PLANNING 1 PIECE SKIN, BUT CLECOED LWR SKIN TO SKELETON, MY WRISTS WERE STUFFED AFTER CLECOING SO I LEFT THE DRILLING FOR NEXT TIME
*THE MATCHED HOLE WINGS ARE FITTING TOGETHER AWESOME, THE LWR SKIN FIT ON WITH NO DIFFICULTY AT ALL

Manual Reference: 7-3, 7-4

RIVETS – INST 58 – REM 3
WING RIVETS – INST 326 – REM 6
TOTAL PROJECT RIVETS – INST 2541 – REM 53

Hours: 3

Total Hours: 259.75

FIDDLING WITH LH WING

-BOLTED OUTBOARD MOUNTING BRACKET TO RIB
-SET UP JACK TO REMOVE SAG, I WAS AMAZED AT HOW MUCH SAG THERE IS WITHOUT SKIN ON, AROUND 5/16″

Manual Reference:

RIVETS – INST 0 – REM 0
WING RIVETS – INST 268 – REM 1
TOTAL PROJECT RIVETS – INST 2483 – REM 50

Hours: 1

Total Hours: 256.75

MORE RIB-SPAR RIVETING

RIVETED 2ND/3RD RIBS FROM OUTBOARD WITH SQUEEZER
CAN’T DO THE REST TILL I HAVE SOMEONE TO BUCK RIVETS WITH ME

Manual Reference: 7-3

RIVETS – INST 10 – REM 0
WING RIVETS – INST 268 – REM 1
TOTAL PROJECT RIVETS – INST 2483 – REM 50

Hours: 1

Total Hours: 255.75

ASSEMBLING LH WING SKELETON

-RIVETED REAR SPAR ASSY TOGETHER

-CLECOED RIBS & REAR SPAR ASSY TO MAIN SPAR
-RIVETED REAR SPAR ASSY TO RIBS

Manual Reference: 7-2, 7-3

RIVETS – INST 102 – REM 1
WING RIVETS – INST 258 – REM 1
TOTAL PROJECT RIVETS – INST 2473 – REM 50

Hours: 3

Total Hours: 254.75

PREP/PRIMING LH WING COMPONENTS

-ASSEMBLED TIE DOWN ASSY

-COUNTERSUNK REQUIRED REAR SPAR COMPONENTS
-ALUMIPREPPED, ALODINED & PRIMED RIBS, REAR SPAR & REAR SPAR ASSY COMPONENTS
-STARTED USING A BOEING BMS 10-11 SPEC PRIMER

Manual Reference: 7-2, 7-3

RIVETS – INST 8 – REM 0
WING RIVETS – INST 156 – REM 0
TOTAL PROJECT RIVETS – INST 2371 – REM 49

Hours: 4

Total Hours: 251.75

PLANNING WING UPPER SKIN SINGLE PIECE MOD

SPENT A FEW HOURS TODAY WHILE I CAN’T PROGRESS WITHOUT PRIMER PLANNING HOW TO MODIFY THE UPPER WING SO AS TO HAVE A SINGLE PIECE MAIN SKIN INSTEAD OF THE SUPPLIED TWO PIECE SKIN,
STARTED WRITING A MOD REPORT FOR MY RECORDS, MOD-002

(Ultimately this turned out to be too expensive and not worthwhile so I scrapped the idea)

Manual Reference:

Hours: 1.5

Total Hours: 247.75

LH WING SKELETON ASSEMBLY/DRILLING

-CLECOED MAIN RIBS TO FRONT AND REAR SPARS
NOTE: REAR SPAR HASN’T BEEN PRIMED OR RIVETED YET SO I ATTACHED EXTRA CLECOES INTO REAR SPAR ASSY TO MAKE SURE EVERYTHING IS IN PERFECT ALIGNMENT

-DRILLED MAIN RIBS TO FRONT AND REAR SPARS

-DRILLED 2 NEW HOLES IN 711 WING WALK RIBS THROUGH REAR SPAR AS REQ
-DISSASSEMBLED WING ASSY
-TRIMMED REAR SPAR REINFORCEMENT PLATES AS REQD, FOUND IT EASY TO MEASURE UP/MARK, THEN PRINT A FULL SIZE TRIM DETAIL OFF DWG 38 AND LAY UNDER TO CHECK MEASUREMENTS, THIS WORKED WELL AND MADE IT EASY, MY PURCHASED CD PLANS FROM VANS ALREADY COMING IN HANDY.

-NOW THAT TECHNICAL WORK IS DONE I GRABBED A BEER AND DEBURRED HOLES ON MAIN SPAR, REAR SPAR, REINFORCEMENT PLATES AND RIBS      

Manual Reference: 7-2, 7-3

RIVETS – INST 0 – REM 0
WING RIVETS – INST 148 – REM 0
TOTAL PROJECT RIVETS – INST 2363 – REM 49

Hours: 4

Total Hours: 246.25

LH WING TIEDOWN/WING RIBS DEBURRING

-TRIMMED AEX BAR TO SIZE TO MAKE W-731
-DRILLED MATCH HOLE ON 731
-CLAMPED 731 BAR & 726 SPACERS TO SPAR ALIGNED AND BACKDRILLED

-DRILLED NUTPLATES TO ASSY & CSUNK SPACER END

-PRIMED 726 & 731

-DEBURRED AL LH WING MAIN RIB LIGHTNING HOLES
-DEBURRED/DIMPLED REAR SPAR UPPER FLANGE HOLES BEHIND REINFORCEMENT FORK
-MARKED 707D READY FOR TRIMMING

Manual Reference: 7-2

RIVETS – INST 0 – REM 0
WING RIVETS – INST 148 – REM 0
TOTAL PROJECT RIVETS – INST 2363 – REM 49

Hours: 2.5

Total Hours: 242.25

DEBURRING/PREPPING MAIN RIBS

-EDGE DEBURRED AND FLUTED ALL MAIN WING RIBS
-ONLY LIGHTNING HOLES TO GO

Manual Reference: 7-2, 7-3

RIVETS – INST 0 – REM 0
WING RIVETS – INST 148 – REM 0
TOTAL PROJECT RIVETS – INST 2363 – REM 4

Hours: 8

Total Hours: 239.75

DEBURRING NOSE RIBS

-FININSHED DEBURRING AND FLUTING ALL NOSE RIBS
-DRILLED REAR SPAR UPPER FLANGE HOLES TO #40 FOR LENGTH OF REINFORCEMENT FORK READY TO DEBURR/DIMPLE
-SORTED MAIN WING RIBS READY TO DEBURR LIGHTNING HOLES & FLUTE

Manual Reference: 7-2, 7-3

RIVETS – INST 0 – REM 0
WING RIVETS – INST 148 – REM 0
TOTAL PROJECT RIVETS – INST 2363 – REM 49

Hours: 1

Total Hours: 231.75

WING NOSE RIB PREP

-SPENT A MONTH AWAY ON HOLIDAYS, SO ON RETURN I DECIDED TO FINISH THE PAINFULL JOB OF FLANGE DEBURRING THE NOSE RIBS
-OVER A PERIOD OF ABOUT A MONTH FINISHED DEBURRING THE NOSE RIB FWD FLANGE EDGES AT WORK IN MY FREE TIME.
-ALL RIB LIGHTNING HOLES STILL TO BE DEBURRED
-FLUTED ALL NOSE RIBS

Manual Reference: 7-2, 7-3

RIVETS – INST 0 – REM 0
WING RIVETS – INST 148 – REM 0
TOTAL PROJECT RIVETS – INST 2363 – REM 49

Hours: 8

Total Hours: 230.75

CONTINUED WING RIB DEBURRING

-CONTINUED EDGE DEBURRING OF WING RIBS
-FINISHED EDGE DEBURRING ALL RIB FLANGES, NOT INCLUDING CORNERS AND TIGHT SPOTS

-COULDN’T HANDLE DEBURRING RIBS ANY MORE SO WENT LOOKING AND FOUND MISSING W-707G REAR SPAR REINFORCEMENT FORKS
-CLECOED/DRILLED W-707G & D FORK AND REINFORCEMENT PLATE TO REAR SPAR & EDGE /HOLE DEBURRED

Manual Reference: 7-2, 7-3

RIVETS – INST 0 – REM 0
WING RIVETS – INST 148 – REM 0
TOTAL PROJECT RIVETS – INST 2363 – REM 49

Hours: 1.5

Total Hours: 222.75

STARTING RIB PREP

-OPENED UP REAR SPAR DOUBLER HOLE

-STARTED DEBURRING WING RIBS

Manual Reference: 7-3

RIVETS – INST 0 – REM 0
WING RIVETS – INST 148 – REM 0
TOTAL PROJECT RIVETS – INST 2363 – REM 49

Hours: 0.5

Total Hours: 221.25

LH WING - STARTING REAR SPAR

-EDGE DEBURRED SPAR & REINFORCE PLATES EXCEPT 707G REINFORCE FORK AS I CAN’T FIND IT
-CLAMPED 707 E/F REINFORCE PLATES TO SPAR, DRILLED/CLECOED & STARTED CUTTING AILERON PUSHROD HOLE

-HOLE DEBURRED SPAR AT 707E & F POSITIONS & HOLE DEBURRED 707 E& F

-HAD TO SKIP CUTTING 707D&G AS I CANT FIND THE G REINFORCEMENT PLATES

Manual Reference: 7-2

RIVETS – INST 0 – REM 0
WING RIVETS – INST 148 – REM 0
TOTAL PROJECT RIVETS – INST 2363 – REM 49

Hours: 2

Total Hours: 220.75

LH WING NUTPLATE ATTACHMENT

-DRILLED 822 ACCESS PLATES TO #28, BUT DIDN’T HAVE DIMPLE DIE TO DIMPLE FOR A # 6 SCREW SO I LEFT THAT FOR NOW
-DRILLED, COUNTERSUNK & RIVETED CENTRE SECTION NUTPLATES ON, THE PLANS CALL OUT FOR YOU TO COUNTERSINK THE W706C DOUBLER PLATE SO THE RIVET HEAD SITS ON THE AFT SIDE OF THE SPAR, AFTER TRYING TO FIND THIS DOUBLER PLATE IN MY PARTS/PLANS AND SEARCHING THE WEB I FOUND THAT IT IS ALREADY RIVETED ON TO THE SPAR FROM FACTORY, AND COULD BE NOTED A BIT BETTER.

-STARTED FABRICATING W-726 TIE DOWN SPACERS

Manual Reference: 7-2

RIVETS – INST 4 – REM 0
WING RIVETS – INST 148 – REM 0
TOTAL PROJECT RIVETS – INST 2363 – REM 49

Hours: 2

Total Hours: 218.75

LH WING LOWER FLANGE FUEL TANK PLATENUTS

-DRILLED, DEBURRED NUTPLATE HOLES ON LOWER FLANGE
-RIVETED THE 30 PLATENUTS ON THE LOWER FLANGE
-COUNTERSUNK SCREW HOLES ON UPPER FLANGE
-DRILLED, DEBURRED & RIVETED ACCESS PLATE NUTPLATES ONTO SPAR
-COUNTERSUNK SCREW HOLE FOR ACCESS PLATES

Manual Reference: 7-1, 7-2

RIVETS – INST 84 – REM 0
WING RIVETS – INST 144 – REM 0
TOTAL PROJECT RIVETS – INST 2359 – REM 49

Hours: 2

Total Hours: 216.75

LH WING UPPER FLANGE FUEL TANK PLATENUTS

-DRILLED, DEBURRED NUTPLATE HOLES ON UPPER FLANGE
-RIVETED THE 30 PLATENUTS ON THE UPPER FLANGE
-COUNTERSUNK SCREW HOLES ON UPPER FLANGE
-THE FIRST FEW DIDN’T COME OUT AS NICE AS I WOULD HAVE LIKED, BUT I FOUND THE SLOWER I FEED THE COUNTERSINK IN THE NICER THE HOLE COMES OUT

RIVETS – INST 60 – REM 0
WING RIVETS – INST 60 – REM 0
TOTAL PROJECT RIVETS – INST 2275 – REM 49

Manual Reference: 7-1, 7-2

Hours: 1

Total Hours: 214.75

STARTING WINGS LHS - NUTPLATE COUNTERSINKING

-MOUNTED LH SPAR INTO STAND
-DRILLED & COUNTERSUNK NUTPLATE ATTACH HOLES

WING RIVETS – INST 0 – REM 0
TOTAL PROJECT RIVETS – INST 2215 – REM 49

Manual Reference: 7-1

Hours: 1

Total Hours: 213.75

EMPENNAGE COMPLETE

***EMPENNAGE COMPLETE***

EXCEPTIONS/NOTES
-ELEVATOR COUNTERWEIGHTS NOT SECURED, WAITING ON HARDWARE
-TRIM TAB HINGE PIN, LONGER PIN NEEDS TO BE INSTALLED & LOCKWIRED
-ELECTRIC TRIM SYSTEM NEEDS TO BE ATTACHED/ADJUSTED
-ROD END BEARINGS IN RUDDER REQUIRE LENGTH SETTING
-NO SWING, ALIGNMENT CHECKS CARRIED OUT
-HORI STAB CENTRE BEARING TO ELEV HORNS NOT DRILLED
-NO BOLTS TORQUED

EMPENNAGE TOTAL RIVETS – INST 2215 – REM 49
TOTAL PROJECT RIVETS – INST 2215 – REM 49

Manual Reference:

Hours: 1

Total Hours: 212.75

LH ELEVATOR FITTING TO STAB

-ROLLED LH ELEVATOR LEADING EDGE & RIVETED

-INSTALLED ROD END BEARINGS PER PLANS
-MADE SLIGHT BEND IN TRIM TAB SKIN AS PER PLANS FOR CLEARANCE
-TEMP FITTED TO HORIZONTAL STAB & STARTED TRIMMING REQD MATERIAL FOR FIT

***LH ELEVATOR COMPLETE***

TOTAL PROJECT RIVETS – INST 2215 – REM 49

Manual Reference:

Hours: 2.5

Total Hours: 211.75

ELEVATOR TRIM TAB ASSY & FITTING

-RIVETED HINGE TO SPAR/SKIN OF TRIM TAB
-RIVETED HORN & RIBS TO TRIM TAB

-HAD INTERFERENCE ON IB RIB FROM HORN RIVET SO REMOVED MATERIAL TO ALLOW SKIN TO SIT FLUSH
-TOUCHED UP ALL BARE METAL EDGES WITH ALODINE 1132 PEN
-RIVETED FWD SECTION OF HINGE TO ELEVATOR SPAR

-INSTALLED TAB

***TRIM TAB NOW COMPLETE***
RIVETS – INST 58 – REM 7
TOTAL PROJECT RIVETS – INST 2215 – REM 49

Manual Reference:

Hours: 2.5

Total Hours: 209.25

TRIM TAB ASSY FITTING/RIVETING

-CLECOED BOTTOM FLANGE OF SPAR TO SKIN & HORNS/RIBS
-RIVETED SKIN TO LOWER SPAR FLANGE

-REALIZED THAT I HADN’T CUT THE OUTBOARD END OF THE TAB STRAIGHT, SO TRIMMED TO 90DEG FROM THE SPAR & TRIMMED RIB ACCORDINGLY, EDGE MARGIN IS COMPROMISED ON THE TAB SKIN, WILL CONTINUE AND CONTACT VANS/SAAA TECHNICAL COUNCILLOR TO FIGURE OUT A COURSE OF ACTION. (SEE DFD-0018)

-CLAMPED STRAIGHT EDGE/ PIECE OF TIMBER EITHER SIDE OF ELEVATOR & CLAMPED 721 HINGE & TAB TO ELEVATOR

-FIDDLED AND TIDIED EDGES FOR AGES TRYING TO GET THE EDGES TO THE RIGHT DISTANCE (3/32″) AND TRIMMED ACCORDINGLY TO MAKE EDGE LOOK GOOD.
-MATCH DRILLED TRIM TAB TO ELEVATOR
-MARKED IB EDGE ON HINGE & MARKED STRAIGHT EDGE ON TAB FOR TRIMMING
-TRIMMED TAB EDGES
-TREATED ALL BARE METAL EDGES AND MATING SURFACES WITH ALODINE 1132 PEN
-RIVETED RIB TO ELEVATOR

RIVETS – INST 20 – REM 0
TOTAL PROJECT RIVETS – INST 2157 – REM 42

Manual Reference:

Hours: 3.5

Total Hours: 206.75

ELEVATOR TRIM TAB PRIMING

PREPPED & PRIMED ELEVATOR TRIM TAB COMPOMNENTS

TOTAL PROJECT RIVETS – INST 2137 – REM 42

Manual Reference:

Hours: 1.5

Total Hours: 203.25

ELEVATOR TRIM TAB WORK

-DRILLED NEW RIBS TO TAB & ELEVATOR
-DEBURRED & DIMPLED/COUNTERSUNK ALL TRIM TAB COMPONENTS

TOTAL PROJECT RIVETS – INST 2137 – REM 42

Manual Reference:

Hours: 2.5

Total Hours: 201.75

TRIM TAB CONSTRUCTION

-REMOVED TAB MATERIAL FROM ELEVATOR TRIM TAB & FABRICATED RIBS TO REPLACE (SEE MOD-001)

-CLAMPED HORNS 618 & 616 TOGETHER & MATCH DRILLED TO SKIN

-MEASURED & CLAMPED HINGE TO TAB

-MATCH DRILLED LOWER SPAR FLANGE TO SKIN
-MATCH DRILLED HINGE/SKIN TO UPPER SPAR FLANGE

TOTAL PROJECT RIVETS – INST 2137 – REM 42

Manual Reference:

Hours: 3

Total Hours: 199.25

ELECTRIC TRIM ASSY CONSTRUCTION

-MEASURED ELECTRIC TRIM BRACKETS TO PANEL & CHANGED AS REQUIRED DUE TO MIRROR IMAGE ISSUES WITH THE PLANS
-DRILLED BRACKETS TO PANEL

-PRIMED BRACKETS

-ROLLED RH ELEVATOR LEADING EDGE
-FITTED RH ELEVATOR TO HORIZ STAB & REMOVED REQUIRED MATERIAL

TOTAL PROJECT RIVETS – INST 2137 – REM 42

Manual Reference:

Hours: 4

Total Hours: 196.25

LH ELEVATOR RIVETING

-CUT OFF ELEVATOR TRIM OPENING TABS & FABRICATED RIB (SEE MOD-001)

-RIVETED 703 TO 704

-RIVETED PLATENUTS/ REINFORCEMENT PLATES TO SPAR
-RIVETED 705 ROOT RIB TO SPAR

-RIVETED 703/4 ASSY TO SPAR

-RIVETED SKIN TO 713 COUNTERBALANCE SKIN
-INSERTED SKELETON INTO THE SKIN
-RIVETED SKIN TO SKELETON
-RIVETED LOWER FLANGE OF TAB SPAR

RIVETS – INST 175 – REM 3
TOTAL PROJECT RIVETS – INST 2137 – REM 42

Manual Reference:

Hours: 4

Total Hours: 192.25

LH ELEVATOR PRIMING

PRIMED LH ELEVATOR COMPONENTS

TOTAL PROJECT RIVETS – INST 1939 – REM 39

Manual Reference:

Hours: 2

Total Hours: 188.25

LH ELEVATOR DEBURRING & DIMPLING

-DEBURRED, DIMPLED & COUNTERSUNK LH ELEVATOR COMPONENTS

TOTAL PROJECT RIVETS – INST 1939 – REM 39

Manual Reference:

Hours: 4.5

Total Hours: 186.25

ELEVATOR LHS STIFFENERS REDO

-NEW JKL STIFFENERS ARRIVED SO I TRIMMED, DRILLED, DEBURRED & PRIMED

-DEBURRED/DIMPLED SKIN
-BACKRIVETED STIFFENERS ON

TOTAL PROJECT RIVETS – INST 1939 – REM 39

Manual Reference:

Hours: 1.5

Total Hours: 181.75

LH ELEVATOR PREP

-CLECOED/DRILLED 610/611 PLATES TO SPAR
-FLUTED/DEBURRED 704/5 TIP RIBS THEN DRILLED TO SPAR
-RIVETED STIFFENERS TO LHS SKIN EXCEPT UPPER JKL IN TRANSIT FROM VANS

-MODIFIED DIMPLE DIE, DIMPLED PLATENUTS & RIVETED TO 615 PLATE

-RIVETED 615 PLATE TO SKIN

-DRILLED COUNTEBALANCE TO TO RIB/SKIN ASSY
-CLECOED SKELETON STRUCTURE TOGETHER
-FINAL DRILLED ROOT RIB & HORN TO STRUCTURE

-CLECOED SKIN TO SKELETON

-FINAL DRILLED UPPER HALF

RIVETS – INST 112 – REM 0
TOTAL PROJECT RIVETS – INST 1939 – REM 39

Manual Reference:

Hours: 2.75

Total Hours: 179.75

TIDYING/MOVING BOXES FROM SHED

-REMOVED FUSE/WING/FINISHING BOXES FROM SHED
-REMOVED WING COMPONENTS FROM BOXES & STACKED
-TIDIED SHED AND REPLACED CARPET
-MADE ROOM FOR WING STAND

Manual Reference:

Hours: 6

Total Hours: 177

RH ELEVATOR COMLETION

-RIVETED 703 RIB TO 704 RIB
-RIVETED 611/610 STIFFENERS & NUTPLATES TO SPAR
-RIVETED INBOARD RIB TO SPAR
-RIVETED 703-704 RIBS TO SPAR
-RIVETED HORN TO SPAR/RIB
-RIVETED COUNTERBALANCE SKIN TO SKIN
-CLECOED SKIN TO STRUCTURE & RIVETED

RH ELEVATOR NOW COMPLETE

NOTE: COUNTERBALANCE SCREWS NOT TORQUED/NEED REPLACEMENT

Manual Reference:

Hours: 3.75

Total Hours: 171

FINISHING RUDDER

DOUBLE FLUSH RIVETED RUDDER TRAILING EDGE, CAME UP GOOD

ROLLED LEADING EDGE & RIVETED, GOT A SMALL CREASE, WITHIN LIMITS

RUDDER NOW COMPLETE
PHOTOS 70, 75-78

Manual Reference:

Hours: 1.5

Total Hours: 163.15

PRIMING ELEVATORS

-PREPPED/ PRIMED LH ELEVATOR SKIN/STIFFENERS & 615 TRIM PLATE

-PREPPED/PRIMED RH ELEVATOR REMAINING PARTS