Wings

Today I finished the attachment of the left wing tip to the left wing. I completed riveting the nut plates to the wing tip and then dimpled the wing to accept the AN507-6R6 screws that hold the wing tip on. Then it was just a simple matter of screwing the wing tip on to the wing.
2 Hours
Wings - 116 hrs
Empennage - 195 hrs
Total hours on project = 311

Wings

Today I worked on the left wing tip again. I put the W-412 rib in place and marked the location of the trailing edge on the tip. After that I took it out and laid out the rivet lines (top and bottom) 5/16" from the edge. Then I drilled and cleco'd the rib to the wing tip. I had to machine countersink the rivet holes in the wing tip and then riveted the rib in place. Since I will be using screws to attach the wing tip to the wing I cleco'd the wing tip back on to the wing and drilled all the holes with a #28 bit, the size of the #6 screws that I'll be using. I pulled the wing tip back off the wing and then I started riveting the K1000-06 nut plates on the wing tip. I was able to measure and drill the holes for the nut plates and put a few on before I was called away for some honey-dos.
5 Hours
Wings - 114 hrs
Empennage - 195 hrs
Total hours on project = 309

Wings

I've decided to attach the wing tips to the wings with screws so they will be easy to remove for access to the various things I plan to put there; lights, antennas. APRS, etc. So with that in mind I knew I'd be using rivets to put nut plates on and that requires a strip of aluminum to keep the rivets from cracking the fiberglass. So today I cut and trimmed some aluminum strips and drilled the #40 holes in order to attach them to the wing tip for the left wing. Once I had the fit right I scuffed up both the fiberglass wing tip and the aluminum strip for a good bond. Then I glued the aluminum strip to the wing tip and held it together with clecos while it dried.
1 Hour
Wings - 109 hrs
Empennage - 195 hrs
Total hours on project = 304

Wings

Today I worked on the wing tip installation for the left wing. I decided to leave the wing in the cradle while I worked on the installation. I had left the aileron in the neutral position from yesterday so it was in place. I measured the flange on the wing tip and calculated how much needed to be trimmed away. The aft portion has a lot to be trimmed to provide clearance from the aileron and the aileron hinge bracket. After making the measurements I marked off the portion that needed to be trimmed off and used my drimel tool with a cutting disc to cut it off. Then I made the final trim with a scotchbrite disc on the drimel tool. To smooth the edges I used a 80 grit sandpaper on a sanding block to dress it up. I guess my measurements were pretty accurate as the test fit gave me the 1/4" clearance the plans call for between the aft of the wing tip and the aileron. I was able to use a couple of clamps to hold the wing tip in place and then started drilling the #40 holes into the wing tip using the holes in the wing as a guide. I started at the leading edge and worked to the back, alternating between the top and bottom. I put a cleco in each hole as I drilled to hold the wing tip in place.
2 Hours
Wings - 108 hrs
Empennage - 195 hrs
Total hours on project = 303

Wings

Today I fine tuned the alignment of the aileron to the left wing. I connected the W-716 and W-818 pushrods to the bellcrank. Using the W-730 bellcrank jig I was able to set the bellcrank in the correct neutral position. Then I used the alignment tool that I made from a board with holes to accept AN-3 bolts so I could put them in the machine holes in the outboard wing rib for the alignment. With lines drawn on the board tangent to the two holes that I drilled I was able to find the correct alignment for the trailing edge of the aileron. I adjusted the rod end bearings on the W-818 push rod to get the perfect fit for the pivot bolts. With everything in place I tightened the jam nuts to keep the rod end bearings in the proper set position.
2 Hours
Wings - 106 hrs
Empennage - 195 hrs
Total hours on project = 301

Wings

Today I was able to attach the left flap to the left wing. I had to measure and adjust the piano hinge to get the alignment just right between the aileron and flap. Once I had the hinge measured and clamped in place I drilled and Cleco'd it in place. Then I took everything back off so I could dimple the holes. Finally I riveted the bottom half of the hinge in place on the bottom skin of the wing, sandwiching the hinge between the skin and the flap gap seal. Then came the hard part of threading the hinge pin in the eyes of the hinge to mate both halves together. The plans called for drilling a small hole in the aileron hinge bracket to enable the hinge pin to slide in and out once the wing is attached to the fuselage. I wasn't able to get it aligned exactly, but that's good as it will prevent the pin from coming out inadvertently.
6 Hours
Wings -104 hrs
Empennage - 195 hrs
Total hours on project = 299

Wings

Yesterday was spent in the shop attaching and adjusting the left aileron to the left wing. Installing the push rods to the bell crank and then adjusting the rod bearings was time consuming. I used my laser level to ensure the alignment holes in the outboard wing rib matched up with the holes in the aileron for the proper set. Van's supplies a jig that you put on the bell crank and push rod to put the bell crank in a neutral position. I discovered that you really need some specialized tools to get the washers and nuts on the bolts for the attachment. I was able to borrow them from my friend Craig at the airport, but then I ordered a set to have for my toolbox.
3 hours
Wings - 98 hours
Empennage - 195 hours
Total hours on project = 293

Wings

I got busy today and managed to finish attaching the brackets on the right aileron. This one went a lot quicker since I had the experience of doing the left one last week. I also finished up on both the left and right flap assemblies. With that done I finished riveting the aileron gap fairing on both the left and right wing.
3 Hours
Wings - 95 hours
Empennage - 195 hours
Total hours on project - 290