Landing lights and fuel tanks

Posted on by Neal

Tonight I installed the landing lights into the wings, and then started the process of dropping the tanks to seal and test them.

The landing lights were already built from the last set of wings. Before I installed them I spend some time rerouting some wires to avoid any possible chaffing. Once I run the wires through the wings I’ll install a clamp to hold the wiring. I need to check that these lights are still working, but skipped that step in my hurry to get the job done. I should be able to plug in my power supply and get it working.

Left wing landing lights installed in their cove
View from inside the wing showing the landing light installed in the left wing

Next, I started the process of dropping the tank on the left wing. There are around 80 screws, and 18 bolts, per tank to remove to get the tank off the wing. Access is a problem with the wing in the stand, so I will need to move the right wing somewhere to finish removing all the screws from the left wing.

My plan is to drop the left wing tank, install the fuel sender, then use soap and water to inspect for leaks. If it all looks ok, I’ll then reinstall onto the wing, and then do the right wing.

Unscrewing tank screws

Landing light brackets

Posted on by Neal

Tonight I installed the landing light brackets into each wing. Access was limited in the garage, but I was able to make it work.

Before we moved last year I Installed an extra support at the front of the wing stand. This allows me to safely slide the wings sideways a foot or so, without the inboard end falling onto the ground. It was useful tonight, as I slid the wings sideways one at a time, gaining access to the landing light area without interference from the other wing.

I used the gun and bucking bar to set all the rivets. Everything was going well until the second to last rivet, when the bucking bar slipped off the rivet head without me noticing. It slipped half off the rivet, and smashed down one side, making an ugly mess. I drilled it out without a problem, but found that the mashed rivet head had gauged the bracket slightly. I used a deburring tool and some scotchbrite to remove the bur that had been created, and then set a new rivet. I’ll touch up the paint next time I am painting. Aside from that silly mistake, this step went well.

Not a lot of room to operate in, but enough to get it done
The damage from the mashed rivet visible on the right side of the dimple
The repaired rivet hole and rivet, not yet set, visible on the left of the picture. This is on the right wing
Finished bracket on the left wing

Finished gap fairings

Posted on by Neal

Tonight I surprised myself by finishing the right wing gap fairings. It was much faster on the second wing, probably because I streamlined my process and moved more quickly through the riveting.

No issues to report, this was a mirror image of the left wing.

Needed to open the garage door to have sufficient access. Luckily it’s a warm and bug-free environment.
Gap fairings installed

Gap fairing riveting

Posted on by Neal

Tonight I completed the left wing aileron and flag gap fairing riveting. I hand squeezed all of the rivets. The only place I did anything differently from the plans was the most inboard rear spar rivet on the aileron fairing, where I used a cherrymax pop rivet instead of a solid rivet. I used a 4-2 cherry max because the clearance on the forward side of the spar was so small, I wouldn’t have been able to safely buck the rivet.

The aileron fairing done, except for the last rivet which I swapped for a 4-2 cherrymax
Close up of the cherry max rivet
Working on the left wing flap gap fairing with the hand squeezer
Left wing fairings installed

Flap gap riveting

Posted on by Neal

Tonight I clecoed on and started riveting the flap and aileron gap fairings, on the left wing. I only had an hour in the garage so I didn’t come close to finishing the riveting, but I made a start.

Left wing aileron gap fairing clecoed into place on the left wing.

Wing dimpling

Posted on by Neal

Tonight I dimpled the aft-most rows of holes in the wing top skins where the gap fairings will attach. I also riveted the stiffeners to the gap fairings, and installed the access port doubler on the left wing.

Dimpled the indicated row on each wing. The gap fairing will be riveted to these holes, and to the vacant row of holes on the spar to the bottom right of the picture
I don’t have the plate nuts for this doubler yet (waiting on Vans), but I decided to attach it to the wing anyway. I should be able to get the plate nuts on, once they arrive, without any issues
Clecoing the stiffeners to the gap fairings before riveting them

Primed parts

Posted on by Neal

Tonight I primed the flap gap fairings, landing light brackets, and the access panel doubler for the left wing.

It took me a while to get set up again, since it’s the first time I’ve spray painted since moving last year. I had to go buy some purified water, and just finding all the stuff I needed took a while. Everything came out looking ok.

Just finished etching, setting the parts out to be painted.

Dimpling flap and aileron gap fairings

Posted on by Neal

After a week being out of action with a flu and cold, I was able to spend an hour or so in the garage tonight. I deburred and dimpled the gap fairings for both wings, then dimpled the holes. I’m hoping to get a chance to prime a bunch of parts tomorrow, so I can start riveting things onto the wings.