I continued progress on the ailerons and flaps - deburring, priming, and riveting. Overall, the process went smoothly - the test fitting identified a few ribs that needed to be fluted, and the flanges on a couple ribs needed to be tweaked a bit to allow for the rivet holes to fully line up for riveting. I also found that there was a hole missing in the skin of both the left and right flaps where a rivet was intended to join with one of the flanges of Rib 1. I used an ultra-stubby bit in my 90 degree drill to access the tight location and drilled the holes without issue.
The riveting itself went well. I did have one rivet mandrel that broke off above the rivet head and therefore needed replacing - of course it was one of the rivets along the flap hinge bracket so access was very tight. I very carefully ground the top of the rivet and mandrel flat with a rotary tool. Once I had a flat surface to work with, it was simple to drill off the rivet head and punch the tail through the skin.
After completion of the flaps and ailerons I moved on to work on the wing structure. Not a lot of visible progress, but lots of effort pulling the protective plastic of all the wing ribs and subs-structure and deburring all the edges and holes. After many hours, all the wing sub-structure (other than the light unit) is cleaned and deburred and ready for test-fitting. That done, it was time to dig one of the wing spars out of the box and get it set up for any required deburring - was exciting to see the spar spread across the workshop!
Next steps will be to clean up the spar edges a bit, and then put together the wing jigs and try a test fit of all the wing components. Test fit will be especially important for the wings as I want to finalize the locations of the wiring runs for all the lights and the pitot tube lines before setting any rivets.
|Aileron and flap components cleaned, degreased and ready for priming.|
|Aileron and flap sub-structure primed and ready for riveting.|
|Flap sub-assemblies ready for riveting. Bushings on the hinge brackets are still covered with tape |
that I put on to protect them during priming
|Saw the missing skin hole as I was clecoing the flap structure together prior to riveting - the gap |
looked odd and after investigating, it was clear that a rivet is required there
|Using the 90 degree drill with an ultra-stubby bit to drill the missing hole in skin,|
using the hole in the rib flange as a guide.
|Aileron and flap skins ready for riveting|
|Bottom of one flap riveted|
|Ailerons and flaps completely riveted|
|Pulling the protective plastic from the ribs - sometimes it comes off smoothly in one piece, sometimes not|
|Checking to see how the wing rib sub-assemblies fit together|
|Wing sub-structure all deburred and cleaned - ready for a test fit |
before degreasing and priming
|Getting out the wing spar for any required deburring - it is long!|