Van's RV-9A in Aurora

The Big Picture

The Big Picture
Flying! 8/28/2011

Tuesday, April 7, 2009

1.6 hrs
On Monday, charged 3 hrs to miscellaneous for constructing the flap/aileron jig with 2x4s and the 1 inch MDF. Spent a bunch of time on this task with the table saw ripping all of the 2x4 parts to the same height. The tricky part is getting the long 2x4s straight on one edge.
Then screwed it all together. And as predicted, this new assembly is unreasonably heavy.

Then on Tuesday, started on the aileron counterbalance tubes. They were already marked. So drilled them, using the new drill press vice from Harbor Freight. Deburred the holes, and then assembled the aileron spar parts. The left side went together perfectly. But one hole was off on the right side. I had seen that it looked odd, and double checked it. Marking those holes is awkward, and I apparently just got it wrong. So turned the tube so that I could reuse two of the good holes and installed clecos. This time, marking was easy and accurate, and after drilling and deburring two more holes, the right side went together. Those two extra holes just make it lighter, right!?!

Will spend the next couple of days in skin edge deburr mode. I'll deburr the aileron skins and leading edges. The flap parts will wait for a lull in the aileron action.

T-minus 4 weeks on the fuselage kit!