Right Leading Edge Prep

No pics today, but the right LE Prep looks just like the left leading edge which I posted a few weeks ago.  I was able to finish the deburring and dimpling on both skin and ribs, also cleaned scuffed and primed the skin.  Before final assembly of the Leading Edge, I will take and blot some additional primer on the ribs where the holes have been match drilled.  The original primer has been removed where the match drilling took place.  Bekah and I plan on going to work on leading edge #2 tomorrow.  Freeing up even more clecos.

Fuel Tank - Trap Doors

Tonight I was able to work on the trap doors..  It's little things like this that take a long time and you never realize.  These guys as I said earlier keep the fuel in the inner most fuel bay in the wing where the fuel pick ups are, so that when you are turning (especially on final) the fuel doesn't run to the outside of the low wing and...  ut oh...

Anyway, these are done at this point, apart from the trimming that will happen when I actually install them on the inner tank ribs.  You will see them installed later on.  I also worked on one of the Leading Edge/Tank attach strips.  Drilling and dimpling for the nutplates.  Many people here get pillowing of the tank skin compared to the leading edge skin.   I have a theory on that.  The nutplates are straight and for the 3/4 inch or so they try to straighten the curve of the tank skin right near the leading edge.   I am going to bend my nutplates a bit hopefully to pull the skin into the curve so you don't get pillowing between the nutplates.  We will see if that works..

Right Tank - Catching up to the left tank

The thing about wings is you have to do two of everything. Tonight I opened up the end rib and drilled the fuel pick up/access cover, countersunk the rivets around the baffle, installed the fuel cap and drain, as well as some other misc items on the right tank. Now I have to tanks that are 95% of the way ready for the pro-seal treatment..

Next step is to work on the fuel tank "trap doors" and just a couple more items on the tanks. Also, I decided to rivet the right leading edge before going onto sealing the tanks, freeing even more clecos and getting the little bit of satisfaction that comes with a finished part before diving into the tanks for good.  Plus this works out better in regards to timing of Thanksgiving which is next week.

I will talk more about the trap doors, but basically they allow fuel into the inboard fuel bay of the tank and slow its retreat out of that bay.  So if you are using the left tank, and turning left on final, you don't want all your fuel to run to the outside of the tank, away from the fuel pick up tubes..  Good idea right?  Also, if nothing else, this build has taught me something about piloting even in certified aircraft.  If both tanks are equal fuel, on approach, you should select the tank that is outboard of all turns (since most turns are always the same direction on any given approach).  i.e. the tank that is on the high wing so fuel is always running towards the pick ups.  ;-)

Right Tank Match Drilling

Match drilling is the same as reaming out the holes.  Each pre-punched hole is undersized and when you align the skin on ribs etc. you match drill making sure both the hole is true and even between both pieces.  This takes away stresses in the airframe and makes sure each hole is as perfect as possible.

I was able to match drill the right tank Z brackets and skins just like I did on the left tank.  Pics are below.  This tank didn't seem to line up on the spar as easily so am worried about how it will turn out down the road.  Basically in airplane building you end up doing so much work, then when its all done and riveted it better line up.  If after I get this tank done the Z brackets don't line up for bolting on..  then I am in trouble..  It has happened to other builders so I am nervous and trying to be careful here.

Even More Tank Prep

I have the left tank completely ready for the Pro-Seal treatment except for the final Deburring and Dimpling, oh, and then scuffing and cleaning.  See, it is never over.  Always more to do.

Here are some photos of the last bit of work on the left tank, final drilling the tank screw attach holes to #19

Here is the fuel drain at the lowest point in the Tank.   Also, a picture from inside the tank, you can see the flop tube anti-hang up strip attached to the second most rib and the inner most tank stiffener.

Also, here is a look at the "final" right and left fuel pick ups.  Flop tube pictured on the right, standard on the left.  I went with both options for a couple of reasons.  One, is weight..  Two flop tubes would have weighed more, and you really only need one if I decide I want sustained inverted flight options on the engine.  Second is reliability; the flop tube moves and the standard pickup doesn't (need I say more?)  I will manage fuel such that the flop tube tank is always used first.  On my fuel selector valve I am going to label it as such:   LEFT TANK - AERO/RIGHT TANK - NORM

Continued Tank Prep

Ok, hit a bit of a snag on the right tank so focused today turned back to the left.   Basically I drilled the root Z bracket off center by about 1/32nd " when compared to the other wing.  It might not have been noticed if I wasn't building the wings both at the same time.  (here is one reason why you might consider building both together)   So an order from Van's should be here shortly with a new Z bracket, some wire and other goodies, but till then back to the left wing.  Note to builders if you drill your Z brackets using similar methods:  The baffle near the top root of the wing is so close to the spar that cleco's will hit the spar and possibly off center the leading edge.  You don't need to ask me how I know this.  ;-)  (It shows it in the plans but is not obvious)

Just the same, lots of Good Looking progress today ! 

Deluxe Fuel Cap drilled for initial fitting:

Complete tank angle attachment with Flop tube inserted. (temporarily)

Right Tank

Begun work on the Right Tank (Rebekah's Tank)..   Oh, and I did get her to commit to filling her tank too.  That's cool, I fill my tank..  She fills hers.  Works for me.  ;-)

After final work was complete on the ribs, I went to initial assembly then through the same process as with the left tank.   Drilling the baffle/Z brackets using the Checkoway method is next.

On this tank, I drilled the leading edge attach angle prior to initial assembly.  Here you can see the holes, and the angle attached with clecos.  Also, I will have to drill out the angle for the 3 skin rivets that will come through and interfere with the attach angle.


While I was at it, I worked on the left tank attach angle.  Here it is different because the flop tube needs to go through the angle on this wing.  So a large hole drilled in the middle allows for the tube to be inserted.