1.6 hrs
Finished edge deburring flap skins. Started deburring holes next. Got 3 skins done.
Van's RV-9A in Aurora
The Big Picture
Flying! 8/28/2011
Wednesday, May 6, 2009
Tuesday, May 5, 2009
Monday, May 4, 2009
2.4 hrs
Remove cover from left tank. That was difficult, but avoided wrecking the cover plate and the inboard rib. Did bend the fuel pickup just a little. I think I'll make a new one and that entails removing the anti rotation bracket and its rivets.
Started cleaning proseal off the parts. This is gonna take a while, and will involve scotchbrite pads and lacquer thinner.
Then commence with left flap preassembly. Need to get as much done as possible, because life will be interfering with build time this week. And a fuselage should be arriving sometime (but still haven't heard from Partain Transport).
Cleco top skin on and weight it down.
Insert trailing edge wedge. Fretted about keeping the other wedge in the right place so that it correctly acts as a spacer. But it seems to just work. Put the spacer wedge in first. Then start the wedge to be used in assembly (working wedge) with the spacer wedge fit as per the drawings. Slide the working wedge in slowly, making sure it stays lined up with the trailing edge as you go. This seems to guarantee the spacer wedge will stay centered in the back V of the working wedge. When you have it all the way in, the spacer wedge should be right were it's supposed to. It it's not, I guess there would be kinks in the trailing edge and the working wedge would have to stick out somewhere along the trailing edge.
Cleco nose skins on. Dropped one of the small punches. Of course it landed just wrong, snapping the tip off. So I ground a point on one of the 3/32 punches. Getting much better at putting those nose skins on. Just in time to not have to do any more.
Match drill trailing edge and cleco to table. That's the last time I have to use that drilling angle guide.Final drill top ribs/skin, spar, nose skin,nose ribs.
Remove cover from left tank. That was difficult, but avoided wrecking the cover plate and the inboard rib. Did bend the fuel pickup just a little. I think I'll make a new one and that entails removing the anti rotation bracket and its rivets.
Started cleaning proseal off the parts. This is gonna take a while, and will involve scotchbrite pads and lacquer thinner.
Then commence with left flap preassembly. Need to get as much done as possible, because life will be interfering with build time this week. And a fuselage should be arriving sometime (but still haven't heard from Partain Transport).
Cleco top skin on and weight it down.
Insert trailing edge wedge. Fretted about keeping the other wedge in the right place so that it correctly acts as a spacer. But it seems to just work. Put the spacer wedge in first. Then start the wedge to be used in assembly (working wedge) with the spacer wedge fit as per the drawings. Slide the working wedge in slowly, making sure it stays lined up with the trailing edge as you go. This seems to guarantee the spacer wedge will stay centered in the back V of the working wedge. When you have it all the way in, the spacer wedge should be right were it's supposed to. It it's not, I guess there would be kinks in the trailing edge and the working wedge would have to stick out somewhere along the trailing edge.
Cleco nose skins on. Dropped one of the small punches. Of course it landed just wrong, snapping the tip off. So I ground a point on one of the 3/32 punches. Getting much better at putting those nose skins on. Just in time to not have to do any more.
Match drill trailing edge and cleco to table. That's the last time I have to use that drilling angle guide.Final drill top ribs/skin, spar, nose skin,nose ribs.
Sunday, May 3, 2009
Right flap construction
5.4 hours
Started today by gluing and screwing the two set of poplar 1x3's together. This was to make a nice flat board for holding the flaps down. .5 charged to misc..
Cleco upper skin to right flap assembly and weight down.
Edge deburr all flap nose skins.
Cleco nose skins to right flap assembly.
Insert both trailing edge wedges into right flap to establish proper spacing.
Match drill trailing edge to table.
Final drill upper skin to ribs.
Final drill nose skins and main skins to spar and nose ribs.
Cleco 906B plate to inboard rib.
Match drill to rib and 906A angle.
Disassemble right flap.
Drill 1/4 hole in inboard rib for 906B attach.
Drill holes for platenut attach.
Started today by gluing and screwing the two set of poplar 1x3's together. This was to make a nice flat board for holding the flaps down. .5 charged to misc..
Cleco upper skin to right flap assembly and weight down.
Edge deburr all flap nose skins.
Cleco nose skins to right flap assembly.
Insert both trailing edge wedges into right flap to establish proper spacing.
Match drill trailing edge to table.
Final drill upper skin to ribs.
Final drill nose skins and main skins to spar and nose ribs.
Cleco 906B plate to inboard rib.
Match drill to rib and 906A angle.
Disassemble right flap.
Drill 1/4 hole in inboard rib for 906B attach.
Drill holes for platenut attach.
Saturday, May 2, 2009
4.1 hrs
Started flap construction in earnest.
Drill and cleco bottom skins to table.
Drill 5/8 holes in table for cleco drop through. Through blind luck, managed to get the long 2x4's in the construction table in almost the perfect place. They could be right along the edge, and they wouldn't interfere with anything there. But the jig weighs alot, and I wanted to inset the 2x4's a bit to provide a good way to grab the assembly for moving it. As you can see from the picture, the right inset is just between the two 5/8 holes that have to be drilled. I was a bit close to one, but it worked well enough.
Clamp and drill 906A angles and 906C spacers to spars. Now these parts make sense.
Cleco bottom skins to flap spars. Cleco ribs to bottom skins and final drill. Flipped the assembly over and the clecoes fit perfectly on the table. The flaps seem to be a bit easier and more forgiving than the ailerons.
Started flap construction in earnest.
Drill and cleco bottom skins to table.
Drill 5/8 holes in table for cleco drop through. Through blind luck, managed to get the long 2x4's in the construction table in almost the perfect place. They could be right along the edge, and they wouldn't interfere with anything there. But the jig weighs alot, and I wanted to inset the 2x4's a bit to provide a good way to grab the assembly for moving it. As you can see from the picture, the right inset is just between the two 5/8 holes that have to be drilled. I was a bit close to one, but it worked well enough.
Clamp and drill 906A angles and 906C spacers to spars. Now these parts make sense.
Cleco bottom skins to flap spars. Cleco ribs to bottom skins and final drill. Flipped the assembly over and the clecoes fit perfectly on the table. The flaps seem to be a bit easier and more forgiving than the ailerons.
Friday, May 1, 2009
Flaps started.
2.5 hrs
Reinstalled the right tank. Just attached with half the screws and bolts.
Removed the left tank so that the BNC leak can be resolved.
Start removing access cover from the left tank. Used proseal on it, and it's a pain to remove.
Started the flaps in earnest.
Clecoed and final drilled flap nose rib/bracket assemblies.
The clecoed nose ribs and 8 outboard most ribs to flap spars and final drilled.
Reinstalled the right tank. Just attached with half the screws and bolts.
Removed the left tank so that the BNC leak can be resolved.
Start removing access cover from the left tank. Used proseal on it, and it's a pain to remove.
Started the flaps in earnest.
Clecoed and final drilled flap nose rib/bracket assemblies.
The clecoed nose ribs and 8 outboard most ribs to flap spars and final drilled.
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