WELCOME!
This website is to log my progress while building a Sonex airplane. I purchased the plans for
Sonex S/N 767 and began construction around Christmas 2004. I would like to keep my costs down
and am currently considering the AeroVee engine. I'm leaning strongly towards tricycle gear.
I've finally settled on using an AeroVee engine and going with the tricycle gear. I know,
everyone thinks a Sonex should be built with a tail wheel but I like the tricycle gear and I'm
sticking with it.
Builders Log Entries
Wing Rib Templates
Type of Work: Tooling
Category: Wings
Manual Reference:
Tonight I started working on the wing rib templates. Using AutoCad and the coordinate table contained in the Sonex plans I drew up the forward rib, SNX-W15-05. I created two versions of the template. One with the flanges to be used as a pattern for the aluminium blank and one without the flanges to be used for the forming blocks.
AutoCAD drawing of nose rib
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Wing Rib Templates
Type of Work: Tooling
Category: Wings
Manual Reference:
Again tonight I worked on my templates for the wing ribs. This time I created the Aft Rib SNX-W16-06.
AutoCAD drawing of main rib
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Cut-out templates for Nose Ribs
Type of Work: Tooling
Category: Wings
Manual Reference:
Today I cut out the templates for the nose ribs. Next, I need to decide whether to try a router to cut the aluminium or to use the snips. If I go with the snips I'll need to glue the templates to bristle board and then use bristle board as the template. If I decide to use the router I need to cut out two pieces of MDF to sandwich the aluminium between and then use as a guide for the laminate trimmer bit.
Began working of first rib
Type of Work: Construction
Category: Wings
Manual Reference:
Tonight I cutout the first rib (SNX-W15-05). I used a set of Andy Snips. These worked amazingly well. In the past I have use either left or right hand aviation snips and these would leave serations along the edges. This meant that I had to cut the blank a considerable amount oversize and then file it to size to remove the serations. The Andy Snips leave no serations to be cleaned up. A quick file and the cutout blank was ready to go. I drilled the two tooling holes and then setup my fly cutter. I am not happy with the pilot bit in the fly cutter. It seems to be off center slightly. I guess that's what I get for buying the cutter at home depot. In anycase, the 3" lightening hole was easy to cut. I can now see why everyone else works in a batch mode. It makes sense to cut out the blanks then setup for the lightening holes and drill them all at once with the setup still in the drill. I plan to finish the current rib and then start working on a batch.
Work on wing ribs
Type of Work: Tooling
Category: Wings
Manual Reference:
I worked on the forming template for the nose rib. The template that I made in AutoCAD was glued to a piece of MDF. Next a second piece of MDF was cut out and clamped to the first one. I drilled the tooling holes and counter sunk them. The two pieces were then bolted together and the finished shape was cut on the bandsaw. I used the bench sander to finish the parts. Next I seperated the two pieces and used a router to put a round edge on one of the pieces. The band saw as set to 10 degrees and a fence installed. I then cut the forming block to provide a 10 degree relief to allow forming to the full 90 degrees. Finally, I transferred the flute positions from the plans to the forming block and then, using the drill press and a rasp bit, I cut the flute locations into the blocks.
Paper Template Glued to MDF
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Spray Glue
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Me, cutting out the template from the MDF
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Cutout forming blocks and first nose rib
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Wing Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Today I made the template for the ribs. SNX-W16-06. I used the same process as the previous entry. I also layed out a number of both ribs on my sheet of 0.025 aluminium. I rough cut out all of the blanks that I had material for and started to work on the finish cutting.
Blanks - Some with relief holes and some without
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Cut Out Remaing Rib Blanks
Type of Work: Construction
Category: Wings
Manual Reference:
I cut out the remaining rib blanks. I picked up another sheet of 0.025 from Triangle Specialty Metals in Cambridge for this. The blanks were rough cut. I started to drill the relief holes. I'll try to finish them tomorrow.
Remaining ribs
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Finished Cutting Out Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Today I finished cutting out the nose ribs. I completed all of the relief holes, marked up the -01,-02,-03, & -04 ribs and cut them out as well. I also started deburing.
Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Work progressed today on the nose ribs. They have all been deburred. I did this using a file and Scotch Brite pads. First I filed the edges to smooth them out. Next a chainsaw file was used in the tight radii to remove burrs. Finally, the Scotch Bright pad was used to remove any scratches along the edges left from the cutting process. This also helped to remove burrs from the edges. All of the parts were tested with my fingers to ensure no sharp edges remained.
The next step was to stack all of the blanks and drill the tooling holes and the center hole for the fly cutter. The blanks were then unclamped and a large (1/2") drill bit was used to deburr these holes.
I then setup the drill press for the 4" lightening hole with the fly cutter and began to cut these holes.
All set to cut the 4 inch lightening hole
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Drilling the tooling holes and the pilot holes for the fly cutter
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After cutting the 4 inch lightening hole
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Cutting Lightening Holes
Type of Work: Construction
Category: Wings
Manual Reference:
Today was spent cutting lightening holes in the nose ribs. The fly cutter worked well. The longest part of the job was clamping and unclamping the ribs. I could have used some of the spring type clamps but since I don't have any, C-clamps had to do.
Me preparing to cut some lightening holes - note the full safety gear
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Just over half done
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A view showing the difference between the -01 through -04 ribs
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Time to deburr the lightening holes and then to hammer form the flanges
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Forming Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
I worked at hammer forming the nose ribs today. I had tried the previously without much success. Today I tried again. The first rib had very small flutes and the flange was not very straight. I tried using my fluting plyers to straighten the flange resulting in marks on the flange. I don't know if they will do any harm but I'd prefer not to use this rib. I also tried a flanging tool made with bearings for the lightening hole and this resulted in a rib that was even more bananna shaped. This rib will be scrapped. My second attempt was better but I still ended up with marks on the flange. I don't plan to use the fluting plyers on the flange again other than for fluting. Today I enlarged the reliefs on the forming blocks and tried again. I used a 1/2" socket extension to hammer the flutes and then the fluting plyers on the flutes to help straighten the rib. This seems to work and I ended up with two good rib. I will scrap the first two but I only have to make one new one as I made an extra anyway.
Forming Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
More forming of nose ribs today. I managed to get four made in one hour. This is going to take a while but they are now turning out well.
Before any hammering
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About the maximum hammering before starting the flutes
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Flutes started
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Flutes and hammering completed
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Almost flat rib. No adjustments made yet.
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Another view of rib. Still need to flange lightening holes.
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Drill setup for cutting fluting grooves into forming block
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Temperature in garage. It was about 2 degrees C (35 F) outside
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More Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
40 minutes and 4 more nose ribs tonight. I've got it down to 10 minutes per rib. I guess that means a total of 260 minutes to form all 26. Only 4 hrs and 10 minutes.
Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Two sessions of forming ribs today. I now have only 10 left to form.
Completed Nose Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
This morning I completed the hammer forming of the nose ribs. I think I have one extra so I won't need to rebuild one of my early attempts that did not turn out. I still need to flange the holes. I ordered the flanging tool last week from Sonex so hopefully it will arive next week sometime.
Completed nose ribs
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Preparing To Cut Out Main Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
I started to drill the corner relief holes in the main rib blanks today. This is a very slow process, drilling four holes per blank.
Flanging Lightening Holes
Type of Work: Construction
Category: Wings
Manual Reference:
My hole flanging dies arrived today from Sonex. I tried flanging the lightening holes in the nose ribs. It seems to work okay but the ribs that started out flat are now slightly dished. I don't know if this is okay or if I'm doing something wrong.
Drilling Corner Relief Holes
Type of Work: Construction
Category: Wings
Manual Reference:
Drilled a bunch more corner relief holes in the main ribs tonight. I only have 6 left to finish.
Working on Main Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Completed drilling the corner relief holes. Next I cut out the corners of all of the ribs. The next step will be to trim the remaining four sides of all the main ribs.
Continued Trimming Main Rib Blanks
Type of Work: Construction
Category: Wings
Manual Reference:
I completed trimming five main or rear rib blanks tonight. I also trimmed the front and rear flanges of all of the rear rib blanks. Only 21 more to trim. Hopefully, tommorrow I should get these done.
Trimming Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
I completed the trimming of the rear ribs today. I also drilled all of the pilot holes for fly cutting the lightening holes and drilled the tooling holes.
Cutting Lightening Holes in Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
I cut all of the 3" lightening holes in the rear ribs and started to cut the 4" holes.
Blanks waiting
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Rear ribs with 3 inch lightening holes cut
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Finished Lightening Holes
Type of Work: Construction
Category: Wings
Manual Reference:
I finished cutting all of the 4" diameter lightening holes in the rear ribs today. That's 52 four inch holes. Wow. It seems like your forever putting aluminum under the drill. Not much to take pictures of so I didn't. Next I need to debur, trim the various ribs that have the larger relief and then I can get on with the forming. Oh yea, I also need to clean up some of the tape glue left over from the packing of the aluminum when I brought it home. Acetone seems to work best as long as I have my mask on.
Deburring Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
It has warmed up a bit outside so I can now get the heat up in the garage. I started deburring rear ribs tonight. It seems to be a very slow process. I think its time to purchase a scotch brite wheel.
More Deburring
Type of Work: Construction
Category: Wings
Manual Reference:
It's quite cold out today (-17C) but I managed to get the garage up to 10. I deburred some more ribs today. I think I finally have it figured out. I'm using a deburring tool for the large lightening holes then a scotch brite pad to finish the holes. Next I use the scotch brite wheel in the grinder for the edges of the rib. It does a wonderful and quick job. Finally, a scotch brite pad just to finish things up. 7 ribs completely deburred, 19 more to go.
Duburring
Type of Work: Construction
Category: Wings
Manual Reference:
Four more ribs completed. The total now stands at Eleven. Only 15 more to go.
Finished Deburring the Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Over the last two days I've managed to get in the time to complete the deburring of the main or rear ribs. I also used some acetone to remove the glue left behind by the tape that was used to secure the roll of aluminum when I brought it home in my van. I'll have to remember next time to only allow the supplier to use stretch wrap and not use the tape. It looks like I should be ready to get to forming next.
Add Fluting Notches To The Rib Forming Blocks
Type of Work: Tooling
Category: Wings
Manual Reference:
I started today by adding the fluting notches to my rib forming blocks. These were done using a rasp type bit in the drill press. I simply held the forming block at the appropriate angle and pushed it against the rasp bit. The finished notch works well.
The drill press setup
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Adding the fluting notches
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The finished notches
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Forming Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
With the forming blocks ready to go I started to form the rear ribs. After clamping them between the forming blocks and putting the assembly into my workmate, its fairly easy to hammer over the flange. Working slowly so as not to stretch the aluminum too much I can almost get the flange completely formed before pushing material into the fluting notches. For the flutes I use a 1/2" drive socket extension and the same forming hammer. The flutes look very nice and the ribs come out almost flat.
The rib blank sandwiched between the forming blocks
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Ribs waiting for forming
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Ready for forming
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Flanges hammered over
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Adding the flutes
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Fluting close-up
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After fluting
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The tools
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Formed ribs
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Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Over the last two days I've managed to get a total of 13 ribs formed. Now I only have 13 more to form. I added an extra bolt to my forming blocks to help keep the middle of the blocks together. I found that even clamped in my workmate the blocks didn't seem to say together.
50% Formed
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More Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Another 4 ribs formed today.
More Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Two More Ribs tonight. I also discovered that I have made one extra rib so I actually have 8 more to form.
Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Four more ribs formed today. Almost done! The ribs that is!
Finishing the Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
I complete the rib forming today and moved on to the flanging. I managed to get all of the lightening holes flanged as well. I still have a little cleanup to do on the ribs. I noticed a few burrs that I didn't get cleanup up earlier. In any case, I'm nearly done with the ribs. Wow!
Completed ribs
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Deburring Again
Type of Work: Construction
Category: Wings
Manual Reference:
I spent a bunch of time today working on deburring the lightening holes in the nose ribs
More Deburring
Type of Work: Construction
Category: Wings
Manual Reference:
Spent time cleaning up the rear ribs
Rib Clean-up
Type of Work: Construction
Category: Wings
Manual Reference:
Today I worked at cleaning up the remaining 10 ribs. I got 4 done but discovered that one was damaged so I'll have to use a spare to make a new -02 rib.
More Rib Clean-Up
Type of Work: Construction
Category: Wings
Manual Reference:
I completed the deburring and cleanup of all but the last two ribs. I've been using a 330 grit aluminum oxide sandpaper to cleanup the inside of the lightening holes and than a 400 grit wet paper to cleanup the corner reliefs. To finish the job I use a scotch brite pad to buff all the edges to a nice smooth finish.
Rebuilt -02 main rib
Type of Work: Construction
Category: Wings
Manual Reference:
I made a new -02 main rib from one of my spares. I should have used the band saw to do the triming after drilling the relief hole, but I didn't think of it in time. Instead, I used my Wiss snips to do the triming. They worked but I think the band saw would have been quicker. Now I'm done with the ribs except for straightening and corrosion protection. I think I'll move on to some other parts for a while.
Deburred ribs
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Templates For Rib Reinforcements
Type of Work: Tooling
Category: Wings
Manual Reference:
Using velumn, I traced the shape for the four different rib reinforcements. Next, I cut these out and glued them to bristol board. Finally, I cut out the bristol board to create my tracing templates.
Layout Of Rib Reinforcements
Type of Work: Construction
Category: Wings
Manual Reference:
Using the templates I made yesterday I started to layout the rib reinforecments. I had some scrap material left from cutting out the ribs. I managed to get all of the reinforecments to fit. At first I ignored marking the locations for the relief holes and simply cut out the reinforcements but it became obvious it would be better to draw in the relief holes when laying out the parts. This way I can drill all of the holes at once and then cut once.
First attempt with relief holes still to be drilled
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Remaining gussets - Time to drill relief holes
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Cut Out The Rib Gussets
Type of Work: Tooling
Category: Wings
Manual Reference:
This afternoon I cut out all of the rib gussets. Next I need to clean up, file and deburr the edges. Then I get to try out my bending brake.
Relief holes drilled
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All cut out
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Sanding and Deburring Gussets
Type of Work: Construction
Category: Wings
Manual Reference:
I started to sand and deburr the rib gussets today.
Rib Gussets
Type of Work: Construction
Category: Wings
Manual Reference:
I finished the sanding and deburring of the rib gussets and then formed them using my bending brake. I started by using my scotch brite wheel to clean up the around the relief hole. Next I used a block sander with 220 grit aluminum oxide paper to sand all of the edges smooth and square. A coarse scotch brit pad was used to finish the edges and the surface. With the part ready to be formed I started to work on the bending brake.
I created a template to gauge the edge of the clamp bar. It needs to have a 1/16" radius filed into it. I put the clamp bar in my vise and with a file, created the necessary edge. With the clamp bar prepared I was ready to form the gussets.
I drew the tangent lines on the gussets for the first 16 and then after a little experimentation formed them with the brake. For the last 16 I only marked each end of the tangent lines.
Clamping the gusset for forming
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A formed gusset
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The gusset lined up for clamping
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Clamped, ready for forming
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A 90 degree bend
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All formed
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Layed Out And Cutout Remaining Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Using the templates I made earlier in the week, I layed out the remaing aileron, flap and tail ribs and cut them out.
Sheet layout out for remaining ribs
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Rough cut
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Finish cuts
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Deburring
Type of Work: Construction
Category: Wings
Manual Reference:
I deburred all of the remaining ribs today. Now I just have to form them. I also ordered a set of offset seaming pliers to help form some of the sharp bends.
Formed Long Bends On Flap And Aileron Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
The heading says it all. I will need to make up another short clamp bar for the bending brake to form the short flange on both ribs.
Upper and Lower Aileron Bell Crank Clevis
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-07/06
I worked on the aileron bell crank clevises today. I was able to make one from some of the scrap I generated when I was working on the motor mounts.
One rough cut part
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Getting the scrap marked to cut
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More Work On The Bell Cranks
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-06/07
I finished up the smaller set of aileron bell cranks today.
One done, one to go - Already marked for first cut
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First cut done, second marked
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Second cut done
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Third cut done, starting to look the right shape
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Rough work complete
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Mirror image finished
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Cutting All Of The 2 x 2 x 1/8 Angle To Length
Type of Work: Construction
Category: Wings
Manual Reference:
I cut all of the 2 x 2 x 1/8 aluminum angle to length
Lots of angle to shape
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Larger Aileron Bell Cranks
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-03/04
From the 2 x 2 x 1/8 angle I made the larger aileron bell cranks for the opposite wing. These are getting fairly easy with all the practice.
Marked out the part
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W20-03
More Work On The Root Rib Attach Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W20-03
Worked at finishing up the second root rib attach angle. Again all but the holes
Spread The Raw Angles And Made The First Of Two Roo Rib Attach Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W20-02
I started by opening up the angle of the material that I had cut to length. I started out using hardwood as shown in the pictures but quickly changed to a steel backup plate (with aluminum covering) when the hardwood broke. I also used some WD-40 as a lubricant to help the angle slide on the plate. The layout work was the same as the previous two parts so making the first one of these angles when fairly quickly.
First attempt to open up the angle
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Angles all layed out
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Rough cut
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Worked On The Second Root Rib Attach Angle
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W20-02
With the first angle done the second one did not take too long.
A comparison of the -02 and -03 angles
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More filing (finish work)
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The set of -02 and -03 angles - a fairly good match
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Made The Rear Root Rib Attach Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-02L/R
I made the root rib attach angles for the trailing end of the root ribs. I started by opening and closing the raw angles to the correct angle. After getting the angles opened up and closed up correctly I layed out the cuts and finished the angles
Raw angles and my protractor
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Opening the angle
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Left and right angles
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Finished angles
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Another view of the finished angles
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Vertical Stiffener Angle
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W11-09
Marked, cut, filed, sanded and scotch brited the part.
Outboard Vertical Stiffener Angle
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W11-11
Marked, cut, filed, sanded and scotch brited the parts. Marked the pilot holes and drilled
L.H. & R.H. Tie Down Fitting
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W11-10L/R
Marked, cut, filed, sanded and drilled out the holes.
Main Spar Center Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-03
I cut out the blanks for the main spar center web from flat 1/8" sheet that I received from Aircraft Spruce.
Left Hand and Right Hand Attach Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
I started with one of my previously created strips of aluminum that is almost the correct width. I cleaned up the long edges using the vixen file, mill file, sandpaper and scotchbrite. The brought the strip to the correct width. Next I started laying out the part using an ultrafine sharpie right on the aluminum. I had to measure one of the angles at the nose of the part as it was not dimensioned on the prints.
More Work Today On the Attach Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
Well, I got back at things again today. I find that an hour at a time is about right and gives me some thinking time. I finished marking out the attach plates and then cut them out on the band saw. I keep remembering to use a candle on the blade before any serious cutting and it sure keeps the blade clean. I used the bench sander after cutting to start cleaning up the edges.
The Attach Plates All Marked Out
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Some Cutting Completed
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Holes In The Attach Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
I started work on the large oval hole and the tail relief. On one of the attach plates I decided to drill a series of 3/32 inch holes around the perimeter of the large oval hole. Next, I used a coping (sp?) saw to cut between each of the holes and get a rough opening. Finally, I used a sanding drum in the drill press to start cleaning up the oval. I also used the band saw to cut the tail relief.
More Attach Plate Work
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
I finished sanding the large oval hole. Next I setup a fence on my drill press to allow me to drill all of the 3/32 inch pilot hole in a straight line. I clamped a piece of hardwood to the drill press table 1/4 of an inch from the centerline of the drill bit. This lets me drill exactly 1/4 inch from the edge of the part. All I have to do is line up each of the marks measured from the end of the attache plate.
The Other Attach Plate
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
For the oval hole in the other attach plate I decided to drill a single hole and then cut the entire oval using a coping saw. This seemed to work quite well. I did some sanding with the drum sander.
When I overlayed the parts I discovered that the two ovals were not the same size. After some measuring I discovered that I had measure one of the holes wrong. I was too small. Whew! Making a hole bigger is easier than making it smaller. After marking the correct hole size is used a round file to open up the hole.
Finishing The Attach Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
I finished the attach plates today by drilling the 3/16 inch holes at the end of the plate and then sanding and scotch briteing the parts.
One Complete, One To Go
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Two Attache Plates Complete
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Flap Drive Plate
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W06-04
Measured and marked the part out on the aluminum. Cut it out on the bandsaw then filed the part to finished size. Marked the holes for drilling.
Flap Drive Plate
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W06-04
Drilled the holes and cleaned up with scotch brite.
Bell Crank Plate
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-11
I completed the bell crank plate. Layed it out, cut, filed and sanded it, then drilled the pilot holes
Doubler
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-04
Marked and cut out both doublers on the bandsaw. I dilled a starter hole and used a copping saw to cut out the large hole in the doubler. Next I used a sanding drum in the drill to finish the hole. I filled and sanded the edges then marked and drilled the pilot holes.
Doubler
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-04
I added the rad to the bottom edge of the doublers. I forgot these when I originally made the parts so I had to go back.
Radius Block
Type of Work: Construction
Category: Wings
Manual Reference: SNX-13-03
These were a bit fiddley(sp). I ripped a strip of aluminum to 1/2" then filed one edge flat and added the radius to the other long edge. Next I setup my fence in the bandsaw to 5/8" and cut out all of the blocks. Finally, I sanded the fresh cut edges. I think I have all of the 1/8" parts complete except for the inner spar webs.
1/8 inch parts
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Main Spar Center Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-03
I started the layout of the main spar center web. To begin with I cleaned up the top and bottom edges with the vixen file and sanded until I had two straight edges that I could work from.
Main Spar Center Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-03
Today I finished the layout of the first web, cut it out and then did the same with the second one.
Main Spar Center Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-03
I finished up the center webs today. I used a whole saw to cut out the 1-1/2" hole but I actually used a 1-1/4" hole saw then opened up the hole to 1-1/2" with a sanding drum in the drill press. I did not drill all of the pilot holes as I will wait until I create one of the other spar webs to use as a template
Aileron Drive Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-04
These were two simple parts also. I layed these out directly from measurements onto the aluminum. Cut the pieces to size on the band saw and rounded the tip using the bench sander. Next I filed and sand the edges. I marked all of the pilot holes and setup a fence on the drill press for 1/4" as this is the edge distance for the holes. Next, I drilled all of the holes. I left the 3/16" hole for later but pilot drilled it 3/32" for now. I finished the parts using scotch brite.
Counter Balance Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07-07
I started each of the four plates by cutting a length of 0.090 aluminum from the strips I had previously ripped on the band saw. Next, I filed the two long edges to get 3-3/8" inches. With this done I simply measured and marked the remaining cuts. These were then cut on the band saw. I filed and sanded the edges to get the final outside shape. Once all four were ready I started to layout the 3/32" pilot holes for the rivets. This was straight forward and I drilled most of the holes in the drill press.
Work on W04-07
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-07
Finished making W04-07
Splice Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12-04
I cut out the splic plates and marked the holes.
Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10
Working on layout of wing spar.
Layout of holes in wing spar
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Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-01
I spent a fair bit of time today finishing the layout of the wing spar. Once all the layout was complete I setup my drill press and drilled the pilot holes. I still need to put in the large 1-1/2" hole but the rest of the holes are complete. My next stop will be to clamp it to the blank for the other side of the wing and use it as a template to get all of the holes drilled in that spar.
Drilling setup for holes in wing spar
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Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W01
Spent more time today getting the other wing spar blank made to size. I'm now ready to setup and start using the first spar as a template to drill the second spar.
Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10
I worked on drilling the second wing spar using the first as a template. This was fairly easy but time consuming. Still, it was easier than all of the layout work that went into the first spar.
Wing Spars Clecoed Together After Drilling
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Making clips from angle stock
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-09
I finished trimming the leg of the angle to the correct lengths. Search for the hardware required and discovered I need to order some phenolic.
Aileron Bellcrank Installation
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21
I picked up my phenolic at aircraft spruce in Brantford this morning. Now I can complete the bellcrank installation. I had previously traced one of the phenolic spacers and I transferred this to the phenolic then cut it out on the bandsaw. It really stinks. Probably not to good to breath. I sanded the spacer on my bench sander. Next I marked the hole for the AN3 bolt that holds the clevis assembly together. After drilling the 3/16 hole for the bolt I then colecoed the clevis to a piece of hardwood to keep the parts in alignment while drilling the rest of the holes. Before drilling the 7/16 hole for the bushing I decided to drill a trial hole in a piece of 1/8 stock. I don\'t have a reamer so I wanted to be sure that the bushings would fit okay in a drilled hole. The drilling process didn\'t work very well. I managed to get to 27/64 before I ran into problems. I started the same process with the clevis and drilled up to 1/4 before stopping for this session
Aileron Bellcrank
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21
I continued to increase the size of the bushing whole in the bell crank using progressively larger drills. When I got to the last one it jammed and stopped the drill. Now I finished the job with sandpaper on a dowel. A reamer would be nice about now. Using sand paper and a small round file worked okay. I managed to get the holes opened up so that the bushings would fit. Next I assembled the bellcrank in the clevis. I had to dig out my copy of AC43.13 to look up the correct torque specs and the correct method to secure the cotter pin. I seems to work pretty good. Next, on to the second assembly. I almost completed the second assembly. I just need to insert some shims to free up the rotation.
Clevis and Spacer
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Clevis Ready For Drilling of Pivot
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Assembled Clevis
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Both Completed Aileron Bellcranks
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Aileron Bellcrank Installation
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21
Today I drilled up the holes in the #9 ribs to #30 for the mounting of the bellcranks.
Rear Spar Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12
.Cut out large rectangular hole in the spar tip, -03L/R. Started to layout spars with all of the fittings in preparation for drilling. Currently I\'m puzzled by the two rivets called out between the bolts at the inboard end of each spar. I\'ll have to take a look at the group postings on yahoo.
Rear Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12
Drilled the pilot holes for the ribs. Started to prepare for assembly of the left rear spar. Drilled the rib holes in the attach plate. Completed the pilot holes in the attach plate. Started installing the doubler.
Attach Plate from the Back of the Spar
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Attach Plate from the Front of the Spar
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Drilling holes in Rear Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12
Completed drilling of pilot holes in the left hand rear spar. Started drilling pilot holes in the right hand rear spar.
Drilling pilot holes in Right Hand Rear Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12
Completed pilot holes in the right hand rear spar. Clean up clearance holes for control rods. Started reviewing plans for ailerons and flaps.
Flap Drive Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W06-05
Riveted one of the drive ribs. Layed out the position of the drive plate on the second rib. Drilled pilot holes through drive plate into drive rib. Completed drill and riveted the second flap drive rib. Started laying out rib locations on right hand flap skin.
Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05-01
Continued laying out the holes in the flap skins. Completed hole layout on right hand flap skin. Drilled pilot holes in the top and bottom of the flap skin.
Drilling holes in right hand flap assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05-01
Tonight I worked on completing the pilot holes in the flap assembly. Next I started to transfer the holes through to the ribs. I worked on the most inboard rib first.
Drilling Flap Skins and Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05
Continued transferring the holes in the flap skin to the ribs. I\'m supporting the flap skin on a couple of 2x6s to provide room for the clecos to protrude down. The best sequence seems to be to insert the rib, clamp it in place using a spring clamp and then drill the holes in the narrowest (front facing) edge. After I get the first four holes drilled in the front edge I switch to either the top and the bottom. I\'m not drilling the holes for the hinge at this time although I have marked the hole position at each rib. I complete all of the #40 holes for the ribs. Next time I\'ll start on the left flap.
Ready to Start Drilling Holes in the Front Edge
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Four Holes Completed
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Ready for Hinge
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Flaps
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
I started today by making up the hinge for the right hand flap I was drilling yesterday. I marked and drilled all of the pilot holes in the hinge. I discovered that I made a mistake when I placed the ribs inside the flaps and they are off by 1/4 of an inch so I needed to adjust a couple of holes in the hinge to line up with the ribs. I left these for later. After drilling the pilot holes I started working on attaching the hinge to the flaps by transfering the pilot holes in the hinge to the flap. Complete the holes between the inboard rib and the next one out. I continued drilling the pilot holes for the hinge after dinner and managed to get the holes 2/3 complete.
Drilling the Flap Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
Tonight I am continuing with transferring the pilot holes in the hinge to the flap skin. After completing the hinge holes I cut the mating hinge piece to length
Upsizing holes in Right Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
Today I started increasing the size of the holes in the right hand flap from #40 to #30. I used my soldering iron to cut away the protective film around all of the rivet holes leaving the rest of the skin protected. It worked well. Next I started to deburr the holes. I completed the first pass on deburring the skin moved on to the ribs.
Prep and Assembly of Right Flap and Start on Left Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
Today I started by deburring all of the edges on the flap skin. Next I pulled the rivets on two sides leaving a flap open for inspection prior to closing. After completing the right flap I started to layout the holes in the left flap. I matched the same mistake I made on the right side in order to ensure the two flaps look the same. After marking all the holes I drilled all the #40 pilot holes through the skin and then I started to install the ribs and complete the pilot holes into the ribs.
Left Hand Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
I started by getting the pilot holes layed out on the hinge. Next, I drilled the pilot holes in the hinge and then transferred the holes to the flap skin. The next step was to enlarge the holes to #30. Next time I\'ll take everything apart and start deburring.
Deburring and Riveting Left Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
After removing all of the clecos and labeling the inner ribs I proceeded to deburr the ribs. The outside was easy using my swivel deburring tool but the inside of the flanges was more difficult. I used some 220 grit Al oxide sandpaper on a popsicle stick to break the burrs off from the edges of the rivet holes. Next I used a scotchbrite pad so finish the ribs. With the ribs completed I proceeded to use a block of wood to hold the flap skin open to provide access to the inside. Again, I used the w220 grit Al oxide sandpaper on the popsicle stick to break the burrs off the edges of the rivet holes. With the skin deburred I reassemble the flap using clecos and started the riveting. Again, I left the flap such that it could be opened for inspection.
Deburring the hinges
Type of Work: Construction
Category: Wings
Manual Reference: Flaps
I deburred the hinges and then wrapped up the flaps for storage until I can get them inspected. Now on to the Ailerons.
Aileron Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Time to start laying out the 6 Aileron Ribs that I need. After tracing out the ribs, I cut them out with the Malco snips. Next I marked and drilled the holes for the radii at the flanges. Finally, I trimmed the ribs to size.
Fabricating Aileron Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-02/03
I started the work today by cleaning up the rib blanks I cut out earlier. I used my bench sander as well as a sanding block and files to get all of the rib blanks to the same size. (Or as close as I could get) After making all of the blanks the same size I set up my bending brake and formed all of the flanges. Three of the ribs needed to be made left hand and three right hand. After forming the first three ribs I had to transfer the bend lines to the back side of the remaining blanks so that they could be formed in the opposite direction. I then formed all of the flanges. Next, I used my scotchbrite to clean up all of the ribs.
Rib Banks After Cutting Them Out
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Blanks Clamped For Clean Up
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Blanks After Clean Up
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Getting Ready To Bend The Blank
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Me - Hard At Work
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More Bending
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Six Ailerons Ready To Go
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Making Molds for Aileron Counterweights
Type of Work: Tooling
Category: Wings
Manual Reference: SNX-W04
I used some hardwood to create the mold for the counterweights. The wood was only 3/4 of an inch thick so I doubled up the thickness. I screwed the two blocks together then I cut out the form using a jig saw. Next I used a third piece for the bottom of the mold. I drilled through all three pieces and bolted them together. I figured it would be easy to remove the bottom after the lead hardens and I would be able to tap the weight out.
Plan For Weight
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Hardwood for Form
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Shape Traced onto Hardwood
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Form After Cutting but not yet Fastened to Base
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Making Aileron Counter Weights
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
I purchased an inexpensive pot and proceeded to melt my lead divers weights on a camp stove. It seemed to take quite a while for the melting to begin but once it started it proceeded fairly quickly. Once I had about 1/2 of one 8 lb weight melted I decided to try pouring. Pouring the lead into the mold was pretty uneventful. There seemed to be a lot of bubbling going on. I\'ll have to see what the results look like after I get the lead out of the mold. The first weight looked great out of the mold. The second one was not quite so nice. I used my plumbing torch to melt some additional lead and fill in the voids.
Melting Lead
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Mold Ready for Pour
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First Pour
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First Weight Out of the Mold
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Second Pour - A Few Voids on the Bottom Side
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Finished Weights
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Counterbalance Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Today I started to drill the holes through the lead weights. I started with a #30 bit so that I could keep the holes lined up with the aluminum counterbalance plates. After; the #30 I moved up to the finished size of 3/16 inches. I used a pecking action and some candle wax as a lubricant and had no problems.
#30 Holes Drilled in Counter Weight
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Ready to Enlarge Holes to 3/16
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Enlarging Holes in Counter Weight
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Getting Ready To Assemble Counter Weight
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Second Counter Weight Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
I started by using the aluminum counter balance plates to drill #40 pilots for the the through holes in the counter weights. After marking all the holes I continued using a #30 drill in the drill press.
Starting the Next Counterweight
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Drilling #30
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Aileron Counterbalance Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
I continued drilling the #30 holes through the lead weights today. Next I enlarged the holes to 3/16.
Completed Drilling
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Channel Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-09
I need to make two channel assemblies, one for each counter balance assembly. I started by finding my Z02-03 angle stock. Next I cut the 4 pieces to length and started to trim them to width.
Cutting Angle Stock
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Cut Angles
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Channel and Counterbalance Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Today I complete the trimming of the channels. I drilled the rivet holes in both angles to make up the channel assembly then I started on the counterbalance assemblies. I measured and drilled the first pilot holes in the aileron ribs for the counterbalance plates. Next I realized that I did not have enough ribs and have proceeded to cut out two more.
More Aileron Construction
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03/04
I completed finishing and forming the last two aileron ribs. Next I started to layout the aileron skins. I have to make sure to measure twice and cut once. One of the tough dimensions is the 2-19/32. I decided that that dimension should be at the start of the radius on the end of the aileron. I then sighted across the aileron to complete the curve around the edge radius.
Outboard End Of Aileron Skin
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Inboard End Of Aileron Skin
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Another View of the Outboard End of The Aileron Skin
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Ailerons
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03-03
I completed all of the pilot holes (#40) in the counterbalance assemblies and moved on to the drive rib assemblies. I also drilled all of the pilot holes in these assemblies. Next, went back to work on the aileron skin and cut out the notch for the drive rib assembly. After cutting out the notch I went back to work on the counter balance assemblies. I enlarged all of the holes to #30 then I proceeded to install the small channels that I made earlier. I would like to put the rivets in the channels from the outside but I don\'t know if there will be enough room. I may try a rivet or two to see if there is enough room for the rivets. A test of the rivets didn\'t work. I guess it\'s best just to follow the plans. I disassembled one of the counterbalance assemblies and deburred one half. Next, I riveted the half together. Tonight, I finished riveting the counter balance assemblies and the drive ribs.
Lining Up the Counter Balance Plate
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Pilot Holes in One Counterbalance Assembly
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Drive Rib Assembly Ready For Drilling
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Notch For Drive Rib Assembly
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Test Fit of Drive Rib Assembly
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Riveted Half
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Completed Counter Balance Assemblies
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Aileron Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-01
I double checked my measurements then cut out the notch for the counterweight. Next I cut the end of the aileron skin. My tip ribs don\'t seem to fit right but this seems to be a common problem. I\'ll continue with the second skin then work on the tip ribs. I\'ll probably have to make new ones. I hope I don\'t have to build the whole plane twice 8^D. I completed about 90% of the layout for the second aileron skin.
Aileron Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Started to cut out the Aileron Skin
Aileron Skins
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Aileron Tip Rib
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Tonight I cut out and formed a new aileron tip rib based on the new drawing I created using my 3D model of the aileron skin. Wow, it fits great. I still need to do a bit of work on trimming the skin but the rib seems to fit great.
Aileron Tip Rib Fit
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Aileron Tip Rib Fit 2
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Aileron Tip Rib Fit 3
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Aileron Tip Rib
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-10
Aileron Rib
1 - Trace and cut out blank
2 - Drill hole for radius before notching
3 - Trim notch and then file edges to side.
4 - Form angles
Aileron Skin
1 - Trim longest cut edge to exact size.
2 - Clean up front edge (shortest edge)
3 - File angle at trailing edge to match tip rib.
4 - Trim the lower edge of the aileron skin to meet the front and back.
Clean up the edges and check the fit of the tip rib.
After completing the tip rib and aileron skin I started to layout the rivet holes. I started do drill the holes for the counterbalance ribs but I discovered that I need a long drill bit.
Ready to Trace Pattern for Tip Rib
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Hole Drilled for Notching
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Ready for Forming
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Forming Beyond 90 Degrees
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Successful Bend Beyond 90 Degrees
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Completed Aileron Tip Ribs
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Aileron Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
I continue to work on the aileron assembly, drilling pilot holes and laying out the holes on the skin. I completed all of the pilot holes in the left aileron skin and clecoed it together. Next I cleaned up and move on to the right aileron skin. I finished all the pilot holes in this skin as well. I should say all the pilot holes except for the hinge on both ailerons. That\'ll be for another day.
Aileron Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
Tonight I removed the clecos so that I could check the overlap of the skin before drilling the hinge. I have found in the past that one of the control surface skins did not have the correct overlap and I did not end up with the correct edge distance. This one seems pretty close. I think I will move the holes about 1/64th closer to the edge of the hinge to provide the best edge distance for both the hinge and the skin.
Aileron Hinge
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-06
Drilled the pilot holes in one hinge and then started to transfer the holes to the small flange on the skin.
Ailerons
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
Tonight I worked at completing the pilot holes for the hinge in the aileron skin. I pretty much completed all of the pilot holes. I discovered there was one left when I took apart the aileron. My next step will be to enlarger all the holes to #30.
Transfering the Holes from the Hinge to the Skin
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Ailerons
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
Re-drilling pilot holes up to #30
Deburring Right Aileron & Completeing Left Aileron
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
I completed deburring the right hand aileron and moved back to the left aileron. The first step was to mark the small flange so that I could determine what overlap I would have. I looks like I\'m shy about 1/64th from the 1/4 inch edge distance that I would like to achieve. Next I marked the hinge and drilled most of the the pilot holes. I left out the one at the middle rib and the ones at the counterbalance ribs. I\'ll mark and drill these while transferring the holes from the hinge to the skin. I transferred all of the holes in the hinge to the skin. Next, I marked and added the holes through the each of the ribs.
Right Aileron Ready for Inspection
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Left Aileron
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
I completed up drilling to #30. Now I need to deburr all of the holes. With all the holes deburred and the ailerons clecoed together I think it\'s time for my first inspection by the MD-RA.
Two Ailerons Ready for Rivets
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Deburring Main Spar Webs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10
Riveting Ailerons
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
After having my MD-RA inspection yesterday I was able to start closing up all of the components that I have made so far. Today I started with the ailerons.
Cleaning Up the Spar Caps
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09
Cleaning Up the Spar Caps
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09-02L
I worked on the left hand lower spar cap. I continued to work at removing the left over flange that had been machined off. I know this is not really required but it makes the tie down fitting fit better and looks nice.
Getting Started
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One Third of Flange Cleaned Up
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Lower Left Wing Spar Cap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W009-L02
Tonight I continued on my clean up of the spar cap. I finished the work on the small 1/16 inch flange.
Spar Cap Cleanup
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Continued Cleanup of the Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09
Today I am continuing with the cleanup of the wing spars. I'm using a small half sheet sander, my sanding block and scotch brite. I completed the two lower spar caps. Next I'll work on the upper spar caps. These I won't be as fussy about the machined of flange. The plans allow it to be proud by up to one sixteenth so I'll just focus on cleaning up the machined edges and getting rid of the scratches.
Cleaning Up The Upper Wing Spar Caps
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09
Wow, I completed one of the upper wing spar caps. They are a a lot of work. It takes a fair bit of elbow grease to get all of the small scratches out. Tomorrow I'll work on the last spar cap. Then I'll be ready to work on the spars themselves.
Cleaning Up The Last Spar Cap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09
I completed the cleanup of the final spar cap. Now on to assembling the spars.
Main Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I worked at getting the left hand spar assembled. I fit the web and drilled a bunch of the pilot holes so that I could cleco the spar together.
Left Wing Spar - First Holes Complete
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Left Wing Spar - Holding Width
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Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I continued to drill the pilot holes in the left wing spar.
Partially Drill Wing Spar
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Left Wing Spar - Another View
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Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I continued to drill the pilot holes in the left wing spar.
Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I started by studying the plans to be sure that I understood the stack of spar webs. Next I realized that I could use the 0.090 thick spar webs to layout and drill all of the pilot holes in the various angles that go at the inboard edge of the spar. My plan is to open up the alignment holes to 3/16" in order to ensure that the root wing attache assemblies and end wing wing attach assemblies can be lined up using the current 3/16" hole that is in the attach blocks. To get to this point I overlapped the two 0.090 web spars and clecoed them using the wing attach holes and the center alignment holes. Next I drilled out the remaining alignment holes to #30. My intent here was to ensure the the attach holes were aligned (using clecos) and then end up with exceptional alignment of the intermediate holes by up drilling both at the same time. Next I inserted copper clecos in the intermediate holes and proceeded to up drill each of the remain three holes to #30 one at a time. After drilling to #30 I moved on to 3/16 for the wing attach points only. This will serve to align the wing attach blocks. Next I used the 090 spar web to pilot drill the first of the angles at the inboard end.
Spar Web (0.090) After Updriling Intermediate Holes To #30
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Alginment Of Wing Attach Holes - Pretty Good!
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Fitting Angles To Left Wing Spar
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Wing Saprs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I completed all of the pilot holes in the left wing spar and moved on to work on the right wing spar. I setup the right spar and proceeded to drill all of the pilot holes at each of the rib stations.
Left Wing Spar - #40 holes completed
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Setting Spar Spacing
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Right Spar - In Progress
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Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I continued drilling the pilot holes in the right wing spar today. I completed all of the pilot holes in the right hand wing spar. The next step will be to mark all of the holes for countersinking and then to experiment with the countersink. I'll complete all of the bolted connections first and then move on to the rivets.
Drilling Pilot Holes in Right Spar
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Both Wing Spars Pilot Drilled
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Right Spar Tip
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Right Spar Tie Down Angle
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Right Spar - Inboard End
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Right Spar - Inboard End #2
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Right Spar - Inboard End #3
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Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I started up drill the wing spars to #30.
Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Continued work on the right hand spar up drilling to #30.
Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Counter Sinking Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I worked on counter sinking the upper right hand spar cap. I completed all the counter sinks but I have a few that I need to go back and enlarge slightly.
Spar Support for Countersinking
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Countersinking with Microstop
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Countersink the Spar (Custom Drill Extension)
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Countersunk Spar
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Counter Sinking the Spar Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I started by marking all of the holes that need to be counter sunk in the 1/8 web. Next I setup the microstop in the drill press and proceeded to drill the counter sinks. I started drilling fairly slowly but I discovered that it was better to drill quick.
Countersunk Web
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Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Tonight I'm working on up drilling the wing spars to #21.
Updrilling to #21
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Updrilling Spar to #21
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Up drilling to #21
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I continued up drilling to both #21 and 3/16". It seems to be taking me a long time. I'm sure if I just drilled by hand it would go quicker but I like the idea of using the drill press to get nice square holes. The holes are actually round it's just that they are at 90 degrees to the surface I am drilling through.
Spar Drilling Setup
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Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I completed all of the up drilling at the root end of the spar and all of the holes along the top spar cap. I just have the holes through the web along the lower edge of the spar to complete.
Root End of Wing Spar
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Up Drilling Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I looks like one more night and I should have all of the drilling of the spar finished.
Up Drilling Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Tonight I completed the up drilling on the right wing spar. Now I need to debur, dimple, alodine and rivet.
Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I started with a bit of cleanup today and then I moved on to completing the countersinking for the counter sunk screws. After setting up my microstop I completed the countersinking of the 1/8 inch center web and the single hole in the top spar cap. With all of the drilling and countersinking complete I moved on to deburring.
Deburring Right Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
After deburring the main spar web I proceeded with the dimpling. I used my new squeezer for most of the dimples and then used a rivet, bolt and hammer to complete the last few. Next I continued the cleanup of the other web sections and then moved on to the spar caps.
Main Spar Web Dimpled
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Rivet Squeezer with Dimpler Installed
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Hammer, Bolt and Block for Dimpling
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Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I started by cleaning up the last few angles for the right spar, then I swap the two spars on the bench so that I can start up drilling the left spar.
I setup the drill press with a new #30 drill bit and proceeded to open up all of the holes at the root end of the spar. I completed about 1/2 of the holes at the root end where the various web doublers are located.
Up Drilling Left Wing Spar to #30
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I completed all of the up drilling to #30 at the root end of the spar. Now I can take it apart and complete all of the rivet countersinks. I completed the counter sinking of all of the rivet holes and then proceeded to start up drilling to #21.
Left Main Spar Assembly
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Up Drilling the Left Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Drilling The Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I finished up drilling the in board end of the left main spar. This is the portion with all of the web doublers. The next step will be to remove all of the doublers and then to up drill the remainder of the spar.
Updriling Main Spar
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Updrilling #40 to #21 on Outboard end Of Left Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I completed all of the up drilling today. Next I will take the spar apart and start the cleanup with scotch brite.
More Spar Drilling
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Preping Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I continued to clean, prep, alodine and paint the components for the left main spar. I finished painting all of the small parts and got the larger web doublers alodined. Next will be the spar caps and the main spar web. I need a warm day that I can work on these outside.
Alodining Small Parts for Spar
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Alodining Web Doublers
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Riveting Left Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Riveting
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Rivets in Left Main Spar Inboard End
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Checking Formed Head Diameter of Rivet
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Checking Height of Formed Rivet Head
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Riveting the Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I started today by working on re-dimpling the top edge of the W10-02 web doubler. I found that the original dimples did not fit well into the spar cap so I used a rivet to reset the dimple before final riveting to ensure a good fit.
After reseting the dimples I continued with the flush rivets.
I made up a new bolt for setting the rivets using a 3/8" bolt for the rivets between the top angle and the spar cap.
Before Re-dimpling Top Edge of Web Doubler
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Rivets Ready For Setting
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Rivet Heads Taped before Setting
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Checking the Fit with the Mating Spar
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Tough to Rivet
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Small and Large Riveting Bolt
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Tough Rivets Completed
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One Spar End Complete
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Riveting Left Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Riveting Left Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Riveting Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I finished all of the rivets in the Left Main Spar except for the ones required for the tip web.
Complete Wing Spar
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Completed Wing Spar - Another View
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Wing Spar Showing Famous Curve
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Preparing Right Spar For Riveting
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Tonight I reset all of the dimples in the right main spar web and cleaned up the web using scotchbrite.
Alodineing and Painting Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I alodine coated all of the small parts for the right main spar and then painted all of the parts with zinc chromate primer. (Canadian Tire Spray Cans) Now I need to wait a few days for the paint to harden well and I can start riveting the right main spar.
Spar Parts Ready For Assembly
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Making Web Spacer and Centre Spacer
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
I used a bunch of scrap .125 aluminum to make twenty centre spacers (SNX-W14-02). This was a bit time consuming but time is free and I had the scrap. After making up the centre spacers I clecoed the right main spar together.
Shims Ready For Cleanup
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Ready To Rivet Spar
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Riveting Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I riveted the lower angle and secured all but one of the -7 bolts. It turns out I am short one bolt. I'll have to order a few more. I also fastened the end wing attach assembly to the inboard end of the spar. I left one of the AN4 bolts out of the block to allow bucking of the nearby rivet.
Riveting Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Continued installing flush rivets.
Flush Rivets
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More Riveting
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I finished all of the flush rivets in the right main spar.
Flush Rivets Complete
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Riveting the Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I finished all of the solid rivets in the W10-05 web doubler.
Continued Riveting of the Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I completed all of the rivets in the inboard end web doublers. I finished about half of the remaining rivets today.
Main Spar
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Riveting Right Main Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I finished all of the rivets except for the tip web assembly.
Finished (almost) Main Spar
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Mating Left and Right Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I completed drilling the 3/16 inch hole through each of the wing attach points using the 3/16 hole in the attach blocks as adrill bushing. I had not up drilled the spar web earlier. After up drilling the attach points I married the spars for the first time. All of the holes lined up very well. I up drilled the three remaining holes to #30 then to #21. Finally I up drilled the center hole to 3/16 of an inch. I decide to take things apart at this point to check things out. All looked good so I decided to up drill the remaining two holes to 3/16.
Mated Spars
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Mated Spars (Another View)
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Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Finising Up The Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I worked on the spars again. I was cleaning up the minor scratches from assembly, torquing all of the fasteners, and generally getting things ready for the assembly of the wings. I completed all of the last riveting and assembly. The only thing left is the final up drilling to 1/4 inch which I need to do when the weather will allow me to extend the spars outside the garage again.
Spars, Ready For Final Up Drilling Then Wing Assembly !!!
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Wing Rib Installation
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
Today I started on the wing rib installation. I began by finding all of the ribs for the right hand wing. I then put the spar on top of two 2x4s that I had screwed to the bench with the forward side up. One by one, I located the ribs and then drilled the pilot holes top and bottom. Next, I marked the centerline on each of the .032 spacers and then drilled the pilot holes in them. Following the .032 spacers were .125 spacers. After drilling all of the pilot holes I turned the spar over and marked the center line for the rivets on the end of each rib. Then I pilot drilled the ribs using the rear spar.
Pilot Drilling The Ribs
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Pilot Drilling The Aft End Of The Ribs
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Wing - Aft Of Spar
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Rib Installation
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
I started today by drilling the remaining pilot holes for the tip ribs. After completing the drilling I proceeded to straighten all of the tip rips. The flanges were not all 90 degrees and some of the flutes needed adjusting to make the ribs flat. After straightening all of the ribs and marking the rivet centerline I installed the tip ribs back onto the spar. The next step was to straighten all of the main ribs and attach them.
Checking the Main Rib Fit
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Tip Ribs
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More Tip Ribs
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Wing (Clecoed)
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Root Rib Gussets
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W17
Today I continued to work on installing the root rib gussets on the root ribs for the right hand wing.
Drilling Root Rib Gussets
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Root Rib Reinforcement
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W17
I continue to prepare the root ribs today. I deburred the rivet holes in the remaining angle gussets and in the ribs themselves. Next, I riveted the ribs to the attach angles and the gussets.
Completed Rear Root Rib
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Completed Tip Root Rib
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Getting Ready for Second Wing Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
I started to dismantle the right wing so that I could assemble the left wing. After dismantling the wing I mated the two spars again and up drilled to 1/4"
Left Wing Rib Installation
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
I started today with a little cleanup then proceeded to work on the final straightening of all the left wing ribs. To straighten the tip ribs I used may seaming pliers and made sure that the flanges were at 90 degrees. Next, I used my fluting pliers to adjust the flues so that the ribs were straight. The final step was to mark the 1/4" centerline on the rips for the rivets. With all the ribs straightened I started to install the rear ribs. I drilled the top and bottom (outermost) pilot holes in each of the ribs as I installed them. Once all of the ribs had been installed I started to prepare the spacers. I marked the centre line on the 0.032 spacers and then drilled the pilot holes at the top and bottom of each spacer using the spar as a template. Next I marked the centre line on the 1/8 inch spacers. I installed the 1/8 spacers one at a time together with the ribs and then finished drilling the pilot holes.
Drilling Pilot Holes for Rear Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
I drilled all of the pilot holes for the rear spar. I then removed all of the rear ribs in preparation to install the tip ribs. I positioned the spar with the forward face down. Using my 0.032 shims I started to position each tip rib one at a time and transfer the pilot holes in the spar into the tip ribs.
Pilot Drilling Tip Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
I continued to install tip ribs tonight. I finished all 12 of the tip ribs leaving only the root ribs to be installed.
Assembling Left Wing
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
Today I re-assembled the left wing so that I could start work on the root ribs.
Fitting Root Ribs on Left Wing
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W17
Today I worked on completing the root ribs for the left wing. I worked on the rear rib first. I measured the 9/16 inch dimension from the rear spar and then fit the rib to this line. Using several .032 shims I aligned the rib with the spars and then clamped the rib to the fittings. After drilling the pilot holes I fit the reinforcement angles and pilot drilled them. Next, I added the remain holes to the reinforcement angles and transfered the holes back to the rib. The final step was to up drill, debur and rivet. For the tip rib I calculated the distance between the ribs using the skin drawing W18 and position the tip rib using the tooling hole, and the adjacent ribs. Having the spacing at the tip of the rib was helpful. The remaining steps were basically the same as for the rear rib.
Completing Left Wing Initial Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
I finished up the assembly of the left wing. Next, I need to get going on the skins and the pitot line support brackets
Cutting Out Wing Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W19
I picked up the first of 6 sheets of 0.025 aluminum sheet from aircraft spruce yesterday. I've been waiting for it to come in so I could start on the wing skins. Today I'm going to layout one of the skins.
Aluminum Sheet Ready for Layout
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Lower Aft Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W19
Today I continued to work on laying out all of the holes in the lower aft skin for the left wing.
Wing Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W19
I picked up some more aluminum sheet yesterday. Today I am double checking all of my dimensions on the first sheet before I start drilling pilot holes. After I checked and adjusted the layout I started to drill pilot holes.
Ready to Check Sheet Before Drilling
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Drilling Pilot Holes in Lower Left Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W19
After drilling all of the pilot holes in the lower left skin I started on the upper left skin. First I identified that the plans show the inside view of the left skin. I unrolled 3 sheets and then rolled two back up. Next I determined which would be the inside. I was fortunate that the side that had some small scratches was also the side with the labeling so it was easy to decide to use this as the inside. Next I did my rough layout so that I could cut out the smaller sheet to work with. After trimming the sheet I started to layout the finished dimensions by first drawing the leading edge and the working on the outboard edge.
Completed Rough Layout of Upper Left Wing Skin
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Upper Left Wing Skin Layout
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W19
Today I completed the layout of the holes in the upper left wing skin. I also trimmed the skin to size. Next time I'll drill all of the pilot holes.
Upper Left Wing Skin Waiting for Drilling
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Upper Left Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W19
Today I drilled all of the pilot holes in the skin.
Cleanup and Forward Wing Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
After cleaning up and rolling and putting away the previous skin I started on the left forward wing skin. The plans indicate that the right skin is shown from the outside which means that the left is shown from the inside if I use the same layout. I completed the rough layout on one sheet and made my rough cuts using my air sheers. Next, I started to layout the cut ends using the tables provided.
Forward Left Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
I completed laying out the outline of the skin then I cut it out. Next I worked on laying out all of the holes. With the holes all laid out I need to take a break and then come back and check some of the dimensions before drilling. After checking the holes I started the drilling completing all of the holes except for at each end.
Leading Edge Wing Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
I finished drilling all of the holes in the left hand leading edge wing skin. Next I started the layout on the right skin. After getting the layout completed I cut out the skin to size.
Drilling Pilot Holes in Right Leading Edge Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
Cleaning Up Wing Skins
Type of Work: Construction
Category: Wings
Manual Reference: snx-W18
Today I started cleaning up the edges of the leading edge wing skins using my sanding block and scotch bright in preparation for forming the skins. I finished the right leading edge skin and started on the left.
Forming Leading Edge Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
Today I used the vacuum forming method and formed one leading edge skin.
Skin Before Forming
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Using Tape To Pull Skin Trailing Edges Together
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Wing Skin With Suction Applied
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Wing Skin After Forming
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Forming the Second Leading Edge Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
Up Drilling Wing Attach Holes to 3/8 in.
Type of Work: Construction
Category: Wings
Manual Reference:
Today I am starting to work on up drilling the wing attach holes to 3/8 inches. The first thing I needed to do was dismantle the one wing that was still clecoed together. Next I setup the drill press and proceeded to drill the holes up using 9/32, 5/16, 11/32 and 3/8 inch drill bits. Unfortunately, one of my holes had the initial pilot hole off quite a bit so I will need to make one new block and redrill it.
Setup For Up Drilling The 3/8 Holes In The Spars
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Spar Up Drilling Setup 2
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Making Replacement Block
Type of Work: Construction
Category: Wings
Manual Reference:
Today I picked up another piece of 1x1-1/4 aluminum bar and cut out a new block. I used the old block to drill the 1/4 inch holes and then after fitting I trimmed the bevel.
Re-Assembling Left Wing so that I can Start Skinning it.
Type of Work: Construction
Category: Wings
Manual Reference:
I re-assembled the left wing using clecos in preparation for fitting the wing skins.
Drilling Upper Left Wing Skin - Assembly
Type of Work: Construction
Category: Wings
Manual Reference:
I worked today at transfering the holes in the wing skins to the ribs and rear spar. I began with the top left wing skin and after finishing this I setup for the bottom left wing skin.
Starting Bottom Wing Skin
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Finished Bottom Wing Skin
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Setting Up the Top Wing Skin
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Wing Assembly with Aft Skins
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Transfering More Holes From The Wing Skin To The Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Today I continued working on the top left wing skin, transfering the #40 holes to the ribs and rear spar.
Transfering Wing Skin Holes to Rear Spar
Type of Work: Construction
Category: Wings
Manual Reference:
Tonight I continued transfering the #40 holes in the lower left wing skin to the rear spar. After finishing the holes I layed the wing down to start fitting the leading edge wing skin.
Fitting Leading Edge Wing Skin
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Transfering Pilot Holes in Leading Edge Skin to Tip Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
I had my son give me a hand and we flipped the wing around so that it was right side up with the leading edge hanging off the bench. Next, I started to line up the leading edge skin. In order to get started on the leading edge I realized that I needed to drill the #40 pilot holes into the spar so I started this process.
Transfering Wing Skin Holes to Main Spar Caps
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
I transfered all of the #40 holes in the leading edge of the top rear wing skin into the top of the spar. With this done, I was ready to start fitting the leading edge wing skin. I slipped the leading edge skin under the rear skin at the top of the spar and proceeded to line things up left to right on the spar and front to back. I did all of this with the wing sitting horizontal on the bench resting on the bottom clecos and with the wing tip ribs hanging off the edge of the bench. With the skin fitted, I drilled the pilot holes along the spar using the holes previously drilled as a guide. After drilling the the pilot holes into the spar I started on the pilot holes in the ribs. When I completed the holes in the ribs I had my wife give me a hand flipping the wing over. I then used some cargo straps to pull the tip skin into place. With the leading edge skin in place I started to drill the pilot holes into the lower side of the tip ribs. I finished all of the holes except the ones into the spar on the bottom side of the wing.
Modifying Tip Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
I noticed that I was getting a bump in the leading edge from the tip ribs. After doing a bit of research I decided to relieve the the ribs at the tip just under the edge of the flange. I drilled 3/16" hole and then trimed back a slot to each hole. This frees up the flange to move a bit and shouldn't create the bump in the leading edge. I'll probably make a new leading edge skin as well.
Reworking Tip Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
More rework of th tip ribs tonight. Completed all of the ribs for the left wing except for the root rib as it is still bolted to the spar.
Re-Working Tip Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
I completed the work on the tip ribs today. I started by filing the slots in the ribs. Next, I used a sanding block to knock the burrs off the outside of the rib and then I used scotchbrite to finish the outside. I used some 220 grit sandpaper around a long drill bit to clean up the inside edges of the slot and the same sandpaper to clean up the burrs on the inside of the rib. I finished up the slots using scotchbrite.
Wing Spar and Clean Up
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
I checked and torqued all of the fasteners on the left wing spar then applied torque seal to all of them. After I cleaned up the shop so that I could layout some more sheet aluminum for cutting.
Laying out Root Doublers
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W20
I drew out both doublers back to back on a sheet of .032 6061-T6. I drew the left doubler second so that the wing walk could be added to the doubler. I continued to cut out both doublers.
Laying Out Another Leading Edge Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
Laying Out Another Leading Edge Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
Pilot Drilling Wing Tip Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
Drilling Pilot Holes in Leading Edge Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
I finished the pilot drilling of the leading edge and then setup to form the leading edge.
Making Right Hand Wing Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W19
I worked on the right hand top wing skin today. I did the layout of the outline from the drawings and then used the left skin as a template for drilling the holes.
Laying out Bottom Right Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W19
Today I drew out the outline and then over layed the left skin in order to drill the pilot holes
Drilling Holes in the Lower Right Wing skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W19
I completed all of the pilot holes in the skin today.
Preparing Left Wing Spar for Assembly.
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W
I spent some time using scotch-brite to clean up a few of the solid rivets. I had just touched the head of the rivets with the #40 drill bit when I was drilling through the flange of the spar. I used some masking tape with a hole punched in it to protect the area around the rivet head while I polished the heads with the scotch-brite. I ended up replacing one rivet in the end. Next i started to work on installing the ribs and up drilling the holes where the ribs are joined to the spar. I clecoed the aft ribs to the spar first and then up drilled a few of the holes. Then I removed the aft ribs and installed the leading edge ribs and up drilled the same holes. I then installed the copper clecos in the larger holes and up drilled the remaining holes. Lastly I swapped the ribs again so that I could finish off the rear ribs. After completing the holes in the main spar I clecoed the rear spar to the ribs and up drilled all of the holes to #30. The final step for this session was to cleco the lower wing skin to the left wing. I want to get all of the skins attached but without the root ribs so that I can put the wing doubler strip in place and drill it using the pilot holes in the doubler using the holes in the skins for a template.
Re-Assembling the Left Wing
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W
Assembling Left Wing
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
Today I flipped the wing over so that it was right side up. Next I started to explore how I could install the root doubler and wing walk for drilling. I removed the clecos from the wing walk area and then I marked the 5/8 overhang onto the doubler for the left wing. I turned out easier to install the doubler and then measure the overhang. The doubler seemed long by about 1/4 inch. I'll need to check the yahoo groups to see if this is the case. After I think I am ready to start marking and drilling the holes. Checking the plans indicates there will be excess.
Landing and Taxi Lights
Type of Work: Construction
Category: Wings
Manual Reference:
Landing Lights
Type of Work: Construction
Category: Wings
Manual Reference:
Today I worked on the taxi and landing lights using the kit I purchased from Duckworks. I fabricated and installed the upper retaining strip for the lense and started on the lower retaining strip.
Upper Retaining Strip from the Top
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Upper Retaining Strip Looking Inside the Wing
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Landing Lights
Type of Work: Construction
Category: Wings
Manual Reference:
Tonight I continued to work on the landing light. I drilled and deburred the retainer for the bottom of the lense cover.
Landing Lights
Type of Work: Construction
Category: Wings
Manual Reference:
Wing Prep
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
In order to get ready for riveting I removed the plastic covering on the wing skins in the areas of the rivet lines using a soldering iron to melt the plastic sheet. With the plastic removed I proceeded to up drill the rivet holes to #30. Next, I unpacked the ailerons so that I could get the second half of the hinge that needed to be attached to the wing and started to mark it's location.
Top of Left Wing after Stripping Plastic Coating
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Preparing Wing For Riveting
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
I installed the hinge for the aileron and then proceeded to up drill the remaining holes in the top of the wing to #30. I flipped the wing over and started removing plastic from the bottom side.
Up Drilled Wing - Ready to be Turned Over
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More Wing Prep
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
I finished stripping the plastic from the bottom of the left wing then proceeded to up drill the skins. I completed most of the up drilling on the bottom side. Next, I need to get down the flap and fit the hinge in order to complete the up drilling.
Flap Hinge
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
Today I continued on working on the rear edge of the left wing. I retrieved the flaps and proceeded to fit the hinge for the flaps. I discovered one of my hinges was too short but I had one that worked. I fit the hinge and pilot drilled to #40 then up drilled to #30. A this point I think I have the wing ready to debur and then rivet. I still need to countersink the holes for the tip ribs/skin and finish the up drilling.
Wing Access Cover Plate
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
I traced and cutout the wing access cover. Next I drilled the four pilot holes. I now need to mount the nut plates but first I need a band saw blade.
Wing Cover Plate Installation
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W18
Wing Tip
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
I've been working on my wing tips for a little while now. At first I wanted to make a one piece wing tip out of aluminum and I started this by creating a cardboard template of the wing tip opening. I decided that a one piece tip would be rather difficult and I was especially worried about forming the flanges. After looking at some other plans that I have (Zodiac XL) I decided to form the flanges as separate angles. These will have nut plates installed so they can be screwed to the wing skins and then I will rivet a single flat sheet of aluminum to the angles to form the wing tip. So far I've made up three of the angles and pilot drilled two of them.
Wing Tip Flange Angles
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Wing Tip
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
I continued working on the left wing tip today. I worked the flutes a bit to improve the fit of the 45 degree flange and then transfered the pilot holes from the top skin to the flange. I plan to keep the tip skin a bit short on the top side so that the radius is visible. I think this will provide the cleanest look.
Working On Wing Tips
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
Wing Tips
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
Today I am working on installing the nut plates in the angles I have made. The first step was to open up the holes for the screws to #30. I then removed the angles from the wing skin. In order to install the nut plates I needed a spacer made from 0.062 in. 6061-T6 sheet. I cut strips 5/16 in. wide and then proceeded to mark them for the holes for the nut plates. The strips will be countersunk on one side to allow the rivets and the screws to be flush on the outside.
0.062 inch Strips Marked for Drilling
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Strips Partially Countersunk
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Countersinking using Microstop
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Spacers for Nut Plates
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Angle with #30 Holes
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Wing Tip Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
Today I continued working on installing the nut plates in the wing tip angles. One of the tricky tasks was to dimple the angles for the countersunk rivets and the countersunk screws I would be using. I have a hand squeezer and dimple dies but due to the sharp bend in the angles (approximately 45 degrees) the squeezer would not work. I decided to try using a regular c-clamp as a squeezer with the bottom die being the countersunk spacer and then use the top dimple die to push the counter sink down into the spacer. I removed the swivel from the threaded portion of the c-clamp and then removed the threaded piece from the c frame. Next, I used a long drill to drill out a 1/8 inch hole in the foot of the c-clamp. I kept the hole towards the outside of the c-clamp so that I would be able to get quite close the the bend in the angle. With the c-clamp modified I was able to start the dimpling operation. I used a small 1/4 inch socket as a spacer around the post of the dimple die so that I was exerting a force on the larger part of the die. This process worked well and I was also able to dimple the larger hole for the #6 screw. This dimple wasn't really deep enough but installing the screw finished the dimple. I managed to get three angles almost complete. I have one nut plate to install in the third angle and then the last angle to finish. Tonight I finished the third angle and started on the last one.
Nutplate Installation from Back Side of Angle
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C-Clamp with Hole in Foot
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Dimpling the Tip Angles
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Holes in Angle and Spacer
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Rivet Fit in Dimpled Angle
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Nut Plate Installation from Mating Side of Angle
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Wing Tips
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
I finished the last angle today and started to fasten all of the angles to the wing skins. Next, I need to cutout the wing tip.
Wing Tips
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
New Wing Tip Attach Angle
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10
The wing tip attach angles I made earlier do not seem to fit properly so I'll make some new ones today so that I can finish the wing tips for the left wing. After making and fitting the new attach angle to the wing tip I proceeded to drill the pilot holes for the counter sunk screws I plan to use. Next I started to make the spacer for the nut plates. With the spacers made I installed the nut plates on the angle. I dimpled for the screws using a countersunk solid rivet just as I did the main spars. This worked well and I installed the wing tip again, this time using screws. The last step is to make an angle for the leading edge to capture the wing tip.
New Wing Tip Attach Angles
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Wing Tip Fastened To Attach Angle
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More Fasteners for the Wing Tip
Type of Work: Construction
Category: Wings
Manual Reference: SNW-W22
Today I am working on the fasteners at the trailing edge of the wing tip. I plan to install three nut plates. I made up another strip of 1/16" by 5/16" al and proceeded to drill and countersink for the nutplates and countersunk screws at the trailing edge. The last think I need to do is create a fastener at the leading edge.
Up Drilling and Dimpling the Tip Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Today I worked on the tip ribs. I had previously removed the leading edge skin. First, with the ribs attached, I up drilled the #40 holes to #33 on the top flange. Next I used my modified dimple dies in my squeezed to dimple the holes. Afterwards I started removing the ribs one at a time and up drilling the remaining holes on the bottom flange and dimpling them.
Dimpling Tip Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Cleaning Up Tip Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Cleaning up tip ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Final Deburring and Prep of Ribs for Left Wing
Type of Work: Construction
Category: Wings
Manual Reference:
Wing Spar Cleanup
Type of Work: Construction
Category: Wings
Manual Reference:
It's been a while since I worked on the plane. Work and family have taken there toll on my available time. Tonight I was back working on the wing spar. When drilling the rivet holes in the spar cap I nicked the edge of one of the web doublers near the root of the wing. I sent photos to Sonex and they advised simply cleaning up the nicks with sandpaper. They said the nicks would not cause any problem. This makes sense as they are outside of the rivet line. As long as there are no stress risers I would not expect a problem either. In order to clean up the nicks I decided to remove a few rivets. I figured they would probably get damaged anyways and sanding without them would be easier. I drilled out the heads and then punched the rivets out. This was pretty easy and quick. Next I used sand paper wrapped around a cut off tongue depressor to sand the edge of the doubler. I cleaned up three of the four nicks. I should be able to finish the last one in the next work session.
Type of Work: Construction
Category: Wings
Manual Reference:
Type of Work: Construction
Category: Wings
Manual Reference:
Type of Work: Construction
Category: Wings
Manual Reference:
I up drilled the last remaining hole in the bottom of my wing spar to #30 then I put the spar away temporarily. With my bench freed up I began deburring the bottom wing skin. I used some scotch brite on a few of the marks left by the clecos. I think the key thing for the second wing is not to rest the wing on the clecos. The marks weren't bad and using a bit of 220 grit sand paper plus the scotch brite, all were easily removed. I also cleaned up the plastic protective covering around the access hole. I manged to get all of the #30 holes deburred on the lower left wing skin. The only thing left to do is drill out the hole for the tie down. This I'll save for next time.
Preping Wing Skins For Riveting
Type of Work: Construction
Category: Wings
Manual Reference:
Cleaning up the upper left Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
Today I worked on deburring the top side of the left hand wing skin. I also sanded out some of the small marks left by the clecos and then used scotch brite to clean them up. I turned the skin over and removed the protective coating from the inside of the skin in preparation to deburr the inside.
Type of Work: Construction
Category: Wings
Manual Reference:
Type of Work: Construction
Category: Wings
Manual Reference:
Riveting the Tip Skin
Type of Work: Construction
Category: Wings
Manual Reference:
Today I riveted the top skin and the top of the leading edge skin to my left wing.
Preparing Right Wing for Skinning
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
I setup the right wing on my bench and set the distance between the rear spar attach hole and the center of the fuselage to 19". Next I unrolled the top skin and proceeded to align the skin.
Pilot Drilling the Right Top Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
Today I completed all of the #40 holes through the top skin and ribs. Next I need to drill through the rear spar and the main spar. For that process I plan to lay the wing flat and check the twist again with a level. I drilled the #40 holes through the rear spar and then leveled the wing on the bench in preparation for fitting the leading edge skin. Next, I got down the leading edge and started on the fitup.
Pilot Drilling the Right Leading Edge Skin
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
I moved the wing forward on my bench so that the leading edge skin could hang over the front without getting caught on my wing support blocks. I then leveled the wing using some aluminum scrap as shims and proceeded to position the leading edge skin.
Drilling Pilot Holes in the Top of the Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07
Pilot Drilling the Right Bottom Wing Skin
Type of Work: Construction
Category: Wings
Manual Reference:
I started off by setting up the wing level on the bench. Actually, the important part was to make sure the main and rear spars where in alignment at both ends. I used a block of aluminum and some tape to mark the level. Once the wing was level, I rechecked the position of the two spar holes. With everything in alignment I proceeded to fit the bottom skin. The tough part was figuring out just how far in or out to place the wing. Once I completed all of the pilot holes in the bottom skin I used my cargo straps to pull the leading edge skin into place. Next, I started to drill the pilot holes in the leading edge skin. I drilled all of the holes in the leading edge except for the holes that go through the main spar.
Leveling Inboard End
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Level Marked with Tape
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Leveling Outboard End
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Ready to Start Drilling
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Ready to Drill Leading Edge
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Done, Except for Main Spar Drilling
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Drilling Pilot Holes in the Bottom of the Main Spar
Type of Work: Construction
Category: Wings
Manual Reference:
Wing Tip for Right Wing
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
Today I started work on the right wing tip. I grabed the template I had made for the left wing and fit it to the right wing tip. It fit well, which is a good sign that both wings are the same. Next I marked the location for the angle to go at the bottom rear of the wing tip. (This is actually the top rear right now since the wing is up side down.) Next I marked out the angle with two 5/8" flanges on a piece of aluminum. I cut out the angle and started the bending process using the forming blocks I made when creating the left wing tip.
Wing Tip Template on Right Wing
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Angle Layed Out on Aluminum Sheet
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Wing Tip Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
Wing Tip Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
Right Wing Tip
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
I up drilled all of the holes on the bottom of the wing for the wing tip angles to #30. I also removed the protective plastic coating. Next I up drilled the holes in the top of the wing for the wing tip angles to #30 and removed the protective plastic coating. I then started to dimple the holes for the countersunk screws. I completed the all of the wing skins and the two bottom angles. The top angles will need to be done with a special C-clamp I made up when making the wing tip for the other wing.
Dimpled Holes Ready For Nut Plates
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Counter Sunk Spacers
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
I worked at making the spacers for mounting the nut plates to the counter sunk holes in the wing tip angles.
Making Nut Plate Spacers
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
Today I continued to make the nut plate spacers. I made up one more strip of 5/16 inch wide by 1/16 inch thick strip and marked up the holes at 1 inch centers.
Making Nut Plate Spacers
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
Today I finished drilling all of the nut plate spacers for the nut plates with the centered threaded hole. After completing the nut plates I riveted them to the first angle for the bottom rear of the wing tip. I have one more nut plate to attach to this angle. It is a nut plate with the threaded hole at one end. I need to make up special spacers for this style nut plate.
Making Wing Tip Mounting Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W22
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