Archive for the ‘Main Wings’ Category

Wing Photos

November 1, 2010

As promised, here are some photos of the recently finished sub assemblies on the wing.

Roll Servo Install

As I wrote in the previous post, safety wiring those two bolts that mount the servo to the bracket was a bear. We’ll see what the tech counsellor says about the quality soon 🙂 Other than that it’s a pretty straight ahead install.

Right fuel tank cover plate and sender install

I got both the tanks closed finally. They still need pressure testing, but I’ll wait till later. I hope I never have to take these things off again. The screws are pretty soft and the philips heads mangle easily.

Aileron control arms primed

I went back and primed the ends of the smaller aileron control arms per Van’s suggestion. One end of each will be exposed to the elements so it is prudent here.

Safe Air pitot mast install in left wing

Pretty straight ahead. I used the template to align the position then rough cut the hole using unibits and the Dremel. With sand drums on the Dremel and the mini files, I smoothed everything to final shape. Match drilled and countersunk the pitot mounting plate and we are all done. I’ll have to wait to rivet until riveting the skin and running the pitot lines.

Right wing control and servo arms

Here’s the business end of the servo arm where it mounts into the aileron control horn at mid span on the right wing.

I started to put the inspection plates back on and twisted the head off of one of the small screws. Argh! So not I’ll either “ez out” the screw or remove the nut plate and reinstall a new one. For now though I am just putting the wings in the corner. Now back to the fuse!!!


Wings Nearing Completion

October 27, 2010

There’s plenty of updates that I’ve been meaning to post to the log. Both bottom wing skins are prepped including the hole for the pitot mast on the left skin. I’ll wait till wiring and pitot lines are installed later to close out the wings. Both fuel tanks are closed. This took longer than I hoped but its done… I think. The Proseal mixture for the right tank baffle seems to be taking a long time to pass the “fingernail test.” I attribute some of that to the change in weather but I might have been off in the 10:1 mixture. I’ll check it in a month or two to see if it sets well. Also I installed the Dynon AP roll servo in the right wing. Safety-wiring the servo mount bolts was a pain with very little clearance. If I were to do it over I might mount the servo to the bracket and then the bracket to the spar. It didn’t help that its been well over 7 years since I safety-wired anything so I had to knock the dust off that part of the brain. I’ve temporarily hooked up all the control rods and the AP linkage. Both wings are sitting pretty back in the stands. The wing tips will be saved till final assembly. Now a night of clean up and reorganizing so I can get the aft fuse riveted. The goal will be to hit the center section hard heading into the holidays. Stay tuned for photos!

Bottom Skin and Fuel Tank

August 17, 2010

Tonight I started drilling the bottom skin for the right wing. I am taking my time on this step to minimize any elongated holes. I am especially careful on the spar hole match drilling. Getting the holes to match up well on the spar was a bit challenging. After reading some similar stories online, I rigged up a stand with some shims stacked under a couple of of the leading edge ribs. This helped take some load off the ribs and spar interface and in turn helped the skin fit a tad better and avoid messing up the holes.

Also on deck tonight was opening up the fuel tank and getting an idea of how to close then out. It looks pretty straight forward— I just need to install the float unit, torque the fittings correctly, secure here and there and screw everything together. I need to research a little to make sure I am not missing anything. One area I am concerned about are the reports of nuisance leaks around fuel tank rivets. Some builders are suggesting this happening to the QB tanks because not enough sealant is being used in assembly. So I took a look around the inside of the tank and was happy to see plenty of sealant covering the flanges, shop heads and corners in the tank. I’ll look at a deeper compartment with a mirror tomorrow.

Not a great shot, but you can see the sealant is well used in the critical areas

Here's my quick solution to relieve stress on rib flanges that might cause bad fit for skin

Flying and Building

August 14, 2010

It’s rare to do both in one day. Today was great flying weather so I tagged along with fellow RV builder, Jason, in his KIS experimental for some lunch in Hoquiam and some cheap avgas in Chehalis. We also saw Jim P. in his awesome RV-7 doing a formation clinic down there. He looked very hot and concentrated heading to his debrief, so we didn’t linger too long.

Back home I got all the conduit in place. It was much more of a workout than I was expecting. Annabelle then helped me get the right wing on the table so I could get the bottom skin on to drill.

Conduit Holes the Hard Way

August 10, 2010

The QB wing comes with one 7/16″ hole for running lights, etc (A second hole on the left wing is provided for pitot line at mid-wing). I originally thought that’d be fine until I actually added it all up. Left wing will have nav/strobe wiring (5 wires), pitot and AOA lines, and pitot heat wiring. The right wing will have nav/strobe wiring and the dynon roll servo harness (5/6 wires I think) to run. I just don’t think it’ll all fit. So a little digging though VAF showed either mounting PVC or the flexi-conduit in the lightening holes using brackets or drilling a 3/4″ hole in the ribs for the flexi-conduit.

I decided on the latter because it’s lighter and, more importantly, I don’t feel like trying to replace a broken/loose bracket later on down the road. The downside is that getting those holes drilled, especially where the inboard bottom skin is already riveted, takes patience some creative problem solving.

Van’s provides a PDF on their site for locating the 3/4″ hole in the ribs. Once I marked the ribs, I drilled a #30 pilot hole through all the ribs. For the inboard wing walk ribs I used a 12″ #30 drill bit to penetrate all 4 of them at once.

Marked and punched the ribs for drilling.

Getting at the ribs through the inspection panels required a right angle attachment.

Once those were done, the fun begins. Using a #3 Unibit, I open up all the holes using a right angle drill attachment I picked up a Lowes for $18. It makes a hell of a racket so make sure the kids aren’t napping (ask me how I know).

Enlarging the pilot hole to 3/4"

I still need to finish up the wing-walk ribs with the unibit once the 12″ drill extension arrives from Avery that will take the 3/8″ shank of the unibit. Hopefully I can finish up the drilling and install the conduit tomorrow evening.

The QB Wing comes with these holes for running wires and pitot air.

Wings, Wings, Wings

August 5, 2010

Work has been picking up again so I spent the better part of the week finishing up details. The left wing gap fairing and flap brace are now installed. All the spacers and hardware were made and assembled for mounting the ailerons. Same with the bellcrank hardware. I greased and torqued the bellcrank bolts as well. I adjusted the smaller control arms relative to the wood guides mounted on the wings ends. Finally I went back to trim and bend the flap hinge pins. I have safetied them on yet as I expect to take them on and off a few more times. Now I need to assess the wire runs.

Sunday Summary

July 25, 2010

Beautiful day in Seattle today. The family went on a beach walk/swimming pool day leaving dear old dad to wrestle with the aluminum in the garage. Awesome!

I started by finishing the riveting on the right wing aileron gap faring. I got all the hardware together and mounted everything back on and clecoed on the bottom skin. The trailing edges of the flap and aileron are much closer now (within about 1/16″) than when I tried it yesterday. Whew.

Last cleco standing on the right aileron gap faring.

I moved on to finishing out the left wing aileron and flap mounting. Countersinking all the holes on the flap brace was tedious but otherwise painless. I wnet back and squeezed the leftover aileron mount brackets with the new 4″ squeezer and closed out the day by getting all the left wing parts cleoced and ready to rivet.

The edge difference between the flap and the aileron got much better after getting everything put together.

The internal linkage for the left wing. Yes that is a hardware store nut. Just temporary so I don't waste the aircraft nuts.

A Miscellaneous Day

July 24, 2010

I got a few hours in today. Worked on details in the right wing. The flap hinge was riveted. I made all the spacers for the bellcrank and ailerons hinges. Tonight I started to rivet the aileron gap faring as well.

There are a couple of issues I need to look into though. First, the bellcrank looks slightly off 90 degrees relative to the bottom of the wing. This is the side with the servo. I think the dynon bracket for the servo that replaces the stock bracket might have been drilled slightly off. This can wait a little bit so I’m not totally sure yet if I need to do anything here.

The second issue is, despite my careful attempts to line up the flap and aileron trailing edges, they might be off by 3/16 or so. I won’t know for sure till I put the bottom skin on. Not much I can do now anyway. My just another unique feature for my airplane.

The new 4″ yoke worked perfectly at petting to the hard to reach rivets on the aileron mounts. Packing it in for the evening. I think I might get a whole day tomorrow on the project. Yay.

An Update Finally!

July 20, 2010

Ok so I ignored the build log for a month. But I have a good excuse. I am actually getting some good hours in on the project without sacrificing family or job time… mostly. Anyway, in my last post I was about to take a week off from work in mid-June to finally focus on the QB wings. I had the optimistic idea that I could get them nearly finished with an 80-hour week put toward the project instead of the 80 hour week I’d put in at the real job. Well I probably only logged about 30 hours in the garage that week and in reality the QB wings at my pace is more like 120 hours worth of work. Still I am making great head way and as of mid July I am closing out a lot of the wing work. Without further ado on to the progress:

With the bellcrank bushing drilled out and the metal prep work finished on the aileron mounts, I started by riveting the aileron mounts together and then on the wing. I have the left a few of the rivets undone as I wasn’t able to squeeze them. After butchering a couple of bucked rivets, I decided to order 4″ yoke to get to these rivets later.

Next up I prepped the aileron and flap braces and matched drilled them to the structure.

The aileron brace fitted and drilled

A down the line shot of the flap brace ready for priming.

Onto the control arms. There are two on each wing. A small steel one connects aileron to the bellcrank. A larger aluminum control rod connects the bellcrank to the center fuse control columns. First, I laid out where the hole needed to be drilled using painter tape to mark the circumference and then evenly divding that for the two rivets on the steel rods or the 6 pop rivets on each end of the aluminum arms. The V-block and some boelube on the drill press made quick work of the drilling.

Measure the circumference then divide by 6 and mark the tape.

Using the V-block to assist in drilling the holes.

Then I matched drill the rod end in place.

I left the riveting till later so I could move on to installing the steel mounting brackets on the ailerons and flaps. These were pretty straight forward, though I used a combination of drill press and match drilling to ensure good line up and clean holes for the all the bolts.

After temp. mounting the ailerons, I got out the primer for the flap and aileron braces and mounts. Done and done. Now onto the flap hinges. I took some time to line up the ailerons into neutral position use the wood stringer and tool hole method Van’s suggests in the instructions. This way I was able to fit the hinge and allow for the 1/4″ space between flap and aileron edges. With that mark on both wings, I could line the hinge up accurately and drill at the holes out.

Priming: The bittersweet moment of building. It means your close to assembling something but it's a PITA.

With that out of the way, I worked on countersinking the flap brace. There’s a small curve ball  for the QB wings at the root end of each wing. The standard build instructions spec universal head rivets but with the QB they want us to use flush rivets. I emailed Van’s. Joe said to just follow the instructions for my kit. OK flush cherry max it is. I couldn’t tell you why though.

Next up more riveting on the braces, finishing out the control rods and getting all the washers and spacers in place.