| Date | Assembly | Instruction | Part | Description | Links |
|---|---|---|---|---|---|
| 10/12/2011 | Wing | W05 | W06-01R W06-01L | W06-01R W06-01L Flap Skins - Used Z02-02 Flap stock. Layed out and cut to shape per plans. | Photos Shop-Video |
| 10/12/2011 | Wing | W05 | W06-01R W06-01L W06-04 W06-02 W06-03 W06-05R and | W06-01R W06-01L Flap Skins - Finished lay out and cut to shape per plans. W06-04 Flap Drive Plates - Drilled #40 holes per plans. W06-05R and W06-05L Flap Drive Rib Assemblies - Using W06-02 and W06-03 (Flap Ribs) along with W06-04 (Flap Drive Plates) completed assemblies. Clamped Drive plates to flap ribs in correct position per plans. Drilled #40 holes through flap ribs using drive plate to locate holes. Updrilled all holes to #30. Updrilled the single holes at end of drive plate to 3/16. Removed clecos and deburred all holes and edges. Riveted drive plats to ribs using CCP-44 rivets. | Photos Shop-Video |
| 10/13/2011 | Wing | W05 | W06-06L and W06-06L | W06-06R and W06-06L Flap Hinges - Cut to proper length and drilled pilot #40 holes. Deburred holes. | Photos Shop-Video |
| 10/13/2011 | Wing | W05 | W05-01R | W05-01R Right Hand Flap Assembly - Did layout of pilot hole locations on flap skin. Started drilling #40 pilot holes. | Photos Shop-Video |
| 10/14/2011 | Wing | W05 | W05-01R | W05-01R Right Hand Flap Assembly - Cont'd drilling #40 pilot holes. | Photos Shop-Video |
| 10/14/2011 | Wing | W05 | W05-01R | W05-01R Right Hand Flap Assembly - Drilled remaining #40 pilot holes. Updrilled #30 holes. Aligned hinge and drilled #40 pilot holes. Also updrilled #30 holes for hinge attachment. Removed all clecos and started deburring all holes and edges. | Photos Shop-Video |
| 10/15/2011 | Wing | W05 | W05-01R | W05-01R Right Hand Flap Assembly - Finnished deburring. Cleanned off all ink markings. Reassembled with clecos for riveting. Riveted assembly per plans. Right Hand Flap Assembly completed. | Photos Shop-Video |
| 10/15/2011 | Wing | W05 | W05-01L | W05-01L Left Hand Flap Assembly - Did layout of pilot hole locations on flap skin. Started drilling #40 pilot holes. | Photos Shop-Video |
| 10/16/2011 | Wing | W05 | W05-01L | W05-01L Left Hand Flap Assembly - Finished drilling #40 pilot holes. Updrilled all #30 holes per the plans. Located hinge using pilot holes per the plans. Drilled all #40 pilot holes and updrilled all #30 holes for the hinge per the plans. | Photos Shop-Video |
| 10/17/2011 | Wing | W05 | W05-01L | W05-01L Left Hand Flap Assembly - Cleaned and deburred all edges and holes. | Photos Shop-Video |
| 10/17/2011 | Wing | W05 | W05-01L W05-2 | W05-01L Left Hand Flap Assembly - Assembled with clecos and riveted per the plans. Left Hand Flap Assembly is now complete. W05-02 Hinge Halves - Cut to length the hinge halves that will be attached to the wings. Also cut to length the hinge pins. All items on drawing W05 are now complete. | Photos Shop-Video |
| 10/18/2011 | Wing | W03 | W04 | Cleaned labels and glue off of vatious parts. | Photos Shop-Video |
| 10/18/2011 | Wing | W03 | W04-01R | W04-01R Right Hand Aileron Skin - Layed out shape and did rough cut. Started filing to final shape and size. | Photos Shop-Video |
| 10/19/2011 | Wing | W03 | W04-01R | W04-01R Right Hand Aileron Skin - Filed end to final shape and dimentions per the plans. Cut openings for Drive Rib and Counterbalance Assembly. Deburred all edges. | Photos Shop-Video |
| 10/19/2011 | Wing | W03 | W04-01L | W04-01L Left Hand Aileron Skin - Layed out shape for end cut. Cut end and filed to final shape and dimentions per the plans. Cut openings for Drive Rib and Counterbalance Assembly. Deburred all edges. | Photos Shop-Video |
| 10/20/2011 | Wing | W03 | W04-02 W04-03 W04-04 | W04-02 -03 Aileron Ribs - Deburred edges and adjusted flanges to 90 degree angle. W04-04 Aileron Drive Plate - Drilled #40 pilot holes and polished/ deburred edges with scoth brite wheel. | Photos Shop-Video |
| 10/20/2011 | Wing | W03 | W04-05R W04-05L W04-06R W04-06L | W04-05R -05L Right and Left Hand Aileron Drive Rib Assemblies - Drilled #40 pilot holes. Updrilled #30 holes. Also updrilled to 3/16th the attachment hole. Rivetted the assembly per the plans. W04-06R -06L Aileron Hinge Halves - Cut the hinge halves to length per the plans. Drilled the #40 pilot holes per the plans. Used the yard stick gig to locate the holes. Skipped the holes that were at different locations. Those holes were located and drilled by hand. | Photos Shop-Video |
| 10/22/2011 | Wing | W03 | W04-08 | W04-08 Aileron Counterbalance - Used a hack saw to cut the lead diagonally to the shape per the plans. | Photos Shop-Video |
| 10/22/2011 | Wing | W03 | W04-11 W04-12 W04-09 | W04-11 and W04-12 - Angles - Cut from angle stock to length and shape per the plans. Drilled #40 pilot holes and Updrilled #30 holes. Deburred all holes and edges. Rivetted the angles together to create W04-09 Channel Assembly. | Photos Shop-Video |
| 10/27/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Started the assembly. First aligned W04-03 Aileron Rib with W04-07 Counterbalance Plate and drilled #40 pilot holes for that half of the assembly. Then aligned W04-02 Aileron Rib with another W04-07 Counterbalance Plate and drilled the #40 pilot holes for that half. Then joined the two haves together with the W04-09 Channel. I used the two pervious assembled halves as a guide to locate and drill the #40 pilot holes. | Photos Shop-Video |
| 10/28/2011 | Wing | W03 | W04-09 | W04-09 Channel Assembly - Made an assembly to replace the one that yesterday had wrong holes drilled trying to make the W03-03 Counterbalance Assembly. | Photos Shop-Video |
| 10/28/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Started the second assembly. First aligned W04-03 Aileron Rib with W04-07 Counterbalance Plate and drilled #40 pilot holes for that half of the assembly. | Photos Shop-Video |
| 10/28/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - For the second assembly aligned W04-02 Aileron Rib with another W04-07 Counterbalance Plate and drilled the #40 pilot holes for that half. Then joined the two haves together with the W04-09 Channel. I used the two pervious assembled halves as a guide to locate and drill the #40 pilot holes. Updrilled all holes to #30 for both W03-03 Counterbalance Assemblies. | Photos Shop-Video |
| 10/29/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Deburred all edges and holes on one of the assemblies. Started drilling and updrilling the holes through the lead for the one assembly. | Photos Shop-Video |
| 10/31/2011 | Wing | W03 | W0-03 | W03-03 Counterbalance Assembly - Finnished drilling holes through the lead on the first assembly. Deburred holes on counterbalance plate. Riveted assembly per the plans. Installed bolts and torqued nuts to 25 in/lbs. One assembly is completed. | Photos Shop-Video |
| 10/31/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Deburred all edges and holes on the second assembly. Drilled and updrilled all the holes through the lead for the second assembly. | Photos Shop-Video |
| 11/1/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Deburred holes for bolts. Riveted assembly per the plans. Installed bolts and torqued nuts to 25 in/lbs. The second assembly is complete. | Photos Shop-Video |
| 11/1/2011 | Wing | W03 | W03-01R W03-01L | W03-01R Right Hand Aileron - Laid out holes to be drilled in the skin. Drilled #40 pilot holes. W03-01L Left Hand Aileron - Laid out holes to be drilled in skin. | Photos Shop-Video |
| 11/2/2011 | Wing | W03 | W03-01R W03-01L | W03-01L Left Hand Aileron - Drilled #40 pilot holes. Debured holes for both Right and Left hand skins. W03-01R Right Hand Aileron - Started drilling #40 pilot holes for the aileron ribs. | Photos Shop-Video |
| 11/3/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Fitted Counterbalance Assembly and drilled #40 pilot holes. Continued drilling #40 pilot holes for aileron ribs. Aligned hinge and drilled #40 pilot holes only in locations for ribs and counterbalance assembly. Also updrilled to #30 holes for hinge only at rib and counterbalance locations. Updrilled to #30 holes on forward and top sides of aileron. | Photos Shop-Video |
| 11/4/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Drilled #40 pilot holes on bottom side of aileron. Updrilled to #30 holes on bottom side of aileron. Cut and trimmed angle on 2X4 wood to use as backing for drilling hinge holes. Removed all celcos. Removed all ribs. Sandwiched aileron skin between 2X4 and hinge spacing board and clamped to the work table. Drilled into the 2X4 at previously drilled locations and celcoed in place. | Photos Shop-Video |
| 11/4/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Drilled #40 pilot holes and updrilled #30 holes for all of hinge. Removed all clecos and deburred all holes. Re-assembled with clecos. Did all rivets per the plan except a couple that are close to counterbalance assembly. These will need a special tool to get done correctly. I need to investigate how I will do these last rivets. | Photos Shop-Video |
| 11/6/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Fabricated a wedge of aluminium to allow riveting the hard to reach rivets around the counterbalance assembly. Riveted the remaining rivets. Started forming the tip for the right hand aileron. | Photos Shop-Video |
| 11/7/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Finished forming the tip. Drilled #40 pilot holes and updrilled #30 holes for the tip. Deburred and cleaned the tip and skin. Riveted the tip in place on the aileron. The right hand aileron is now complete. | Photos Shop-Video |
| 11/8/2011 | Wing | W03 | W03-01L | W03-01L Left Hand Aileron - Trimmed Skin just below the counterbalance assembly to allow assembly to fit properly in the skin. Placed ribs in the skin. Drilled #40 pilot holes in the ribs using the pilot holes in the skin for location. Started up-drilling pilot holes to #30 holes. | Photos Shop-Video |
| 11/9/2011 | Wing | W03 | W03-01L | W03-01L Left Hand Aileron - Finnished updrilling all #30 holes. For the hinge first drilled #40 pilot holes and then updrilled to #30. Deburred all holes. Riveted the Aileron per the plans. | Photos Shop-Video |
| 11/10/2011 | Wing | W03 | W03-01L | W03-01L Left Hand Aileron - Fitted tip to aileron. Drilled #40 pilot holes. Updrilled #30 holes. Deburred all holes and riveted tip to aileron per the plans. | Photos Shop-Video |
| 11/10/2011 | Wing | W12 | W13 | W13 Rear Spar Details - Located kit supplied parts. W13-01R and -01L Right and Left Hand Attach Plates - Cleaned laser cut holes residue. Drilled #40 pilot holes using the drill press. Step up drilled the 3/16th in. hole with #40 #30 #21 and #11 drill bits. Polished edges with scotch brite. W13-05R and -05L Right and Left Hand Tip Rib Attach Angles - Started cutting out shape from Z01-03 Angle Stock. | Photos Shop-Video |
| 11/12/2011 | Wing | W12 | W13 | W13-01R and -01L Right and Left Hand Attach Plates - Polished inside edges and large hole edge. W13-04 Doubler - Polished edges and hole edge. | Photos Shop-Video |
| 11/12/2011 | Wing | W12 | W13 | W13-05R and -05L Right and Left Hand Tip Rib Attach Angles -Finished cutting out shape from Z01-03 Angle Stock. Drilled #40 pilot holes. W13-03 Radius Blocks - Started shaping and cutting to plan dimensions. Completed one of the 4 required. | Photos Shop-Video |
| 11/13/2011 | Wing | W12 | W13 | W13-03 Radius Blocks - Shaped and cut to plan dimensions. Completed the remaining three of the 4 required. | Photos Shop-Video |
| 11/15/2011 | Wing | W12 | W12-03R W12-03L | W12-03R and -03L Right and Left Hand Outboard Rear Spar Channel - Laid out the shape to cut from the 32 inch piece of SNX-Z01-02 Spar Channel supplied with the kit. Also marked the location of the opening for the aileron counterbalance. | Photos Shop-Video |
| 11/15/2011 | Wing | W12 | W12-03R W12-03L | W12-03R and -03L Right and Left Hand Outboard Rear Spar Channel - Cut the 45 degree end for both parts. Drilled holes at the corners of the counterbalnce openings. Used the cut off wheel to cut out the material between the holes. Using files started to finnish the opening to the correct size. | Photos Shop-Video |
| 11/16/2011 | Wing | W12 | W12-03 W12-02 | W12-03R and -03L Right and Left Hand Outboard Rear Spar Channel - Finnished filing openings to correct size and shape. W12-02R and -02L Righ and Left Hand Rear Spar Channel - Cut to proper length with angle on inboard ends. Filed cut ends to exact proper lengths for upper and lower sides | Photos Shop-Video |
| 11/17/2011 | Wing | W12 | W12-02R W12-02L | W12-02R and -02L Right and Left Hand Rear Spar Channel - Layed out locations for pilot holes for ribs. Layed out locations of holes for W13-04 doublers and W13-01R and W13-01L Attach plates. Drilled starter holes for doublers and attach plates. Used files and die grinder with scotch brite wheel to enlarge and polish the two holes on W12-02L. | Photos Shop-Video |
| 11/18/2011 | Wing | W12 | W12-02R W12-02L | W12-02R and -02L Right and Left Hand Rear Spar Channel - Used files and die grinder with scotch brite wheel to enlarge and polish the two holes on W12-02R. Made a template tool to drill the #40 pilot holes for where the ribs will attach to the rear spar. Using a formed rib as a pattern I drilled #40 holes into a piece of scrap rear spar channel material. I then bent a peice of scrap .025 aluminum to wrap around both sides of the scrap spar channel. I then reverse drilled the holes from spar channel scrap to form the template. I tested the template by drilling new holes on the spar channel scrap. The rib was clecoed to the scrap to test the hole locations. It worked great. I then drilled several #40 pilot holes into W12-02R Rear Spar Channel. About half way through the holes in the template were starting to get out of round. So I drilled new holes in the template the same way I did previously. I finnished all the holes in the W12-02R Rear Spar Channel. I celcoed ribs to all the locations to test the fit of the holes and if the ribs where square. Everything was good. | Photos Shop-Video |
| 1/2/2012 | Wing | W12 | W12-02R W12-02L | W12-03R and -03L Right and Left Hand Outboard Rear Spar Channels - I drilled the #40 pilot holes where the ribs will attach. I used the template to locate the holes. W12-02L Left Hand Rear Spar Channel - I drilled all the #40 pilot holes where the ribs will attach. I again used the template to locate the holes. I celcoed the ribs to all the locations to test the fit of the holes and if the ribs where square. Everything was good. | Photos Shop-Video |
| 1/3/2012 | Wing | W12 | W12-02R W12-02L | W12-04 Splice Plate W12-03R and -03L Right and Left Hand OutBoard Rear Spar Channels and W12-02R and -02L Right anf Left Hand Rear Spar Channels - Started drilling #40 pilot holes using the W12-04 Spice Plates to join the -02 Rear Spar Channels to the -03 Outboard Rear Spar Channels. | Photos Shop-Video |
| 1/4/2012 | Wing | W12 | W12-01R W12-01L | W12-01R and -01L Right and Left Hand Rear Spars - Continued on Rear Spars. Finnished drilling #40 pilot holes for W12-04 Splice Plates. Updrilled Splice Plate holes to #30 size. W13-04 Doubler - Located and drilled both #40 pilot holes and updrilled to #30 holes per plans. Did not updrill the two holes located where a rib will be attached. W13-05R and -05L Tip Rib Attach Angles - Located per the plans and drilled the #40 pilot holes. W13-01R Right Hand Attach Plate - Located per plans and drilled #40 Pilot holes. W13-02R Root Rib Attach Angle - Located per the plans and drilled the #40 pilot holes. | Photos Shop-Video |
| 1/5/2012 | Wing | W12 | W12-01R W12-01L | W12-01R and -01L Right and Left Hand Rear Spars. W13-01L Left Hand Attach Plate - Located per plans and drilled #40 Pilot holes. W13-02L Root Rib Attach Angle - Located per the plans and drilled the #40 pilot holes. For both spars - updrilled all required #30 holes per the plans. | Photos Shop-Video |
| 1/6/2012 | Wing | W12 | W12-01R W12-01L | W12-01R and -01L Right and Left Hand Rear Spars. Drilled and updrilled holes for AN3-7A Bolts attaching W13-02R and W13-02L Root Rib Attach Angles. Fitted and drilled/updrilled holes for W13-03 Radius Blocks. W12-01L Left Hand Rear Spar - Cleaned and deburred all parts. Rivetted the left spar per the plans. Also installed the two AN3-7A Bolts. | Photos Shop-Video |
| 1/7/2012 | Wing | W12 | W12-01L | W12-01R Right Hand Rear Spar - Cleaned and deburred all parts. Rivetted the right spar per the plans. Also installed the two AN3-7A Bolts. | Photos Shop-Video |
| 1/9/2012 | Wing | W08 | W11-03 W11-04 | W11-03 Wing Attach Blocks - Cut from 1 x 1.25 6061 T6 Bar Stock using the band saw to cut to length and cut 3/16th chamfer. Used belt sander to smooth cuts to proper size. W11-04 Shim Plates - Cut from .063 6061 T6 sheet using the hack saw. Used scotch brite wheel to smooth and trim the cut edges. | Photos Shop-Video |
| 1/10/2012 | Wing | W08 | W11-03 | W11-03 Wing Attach Blocks - Using the drill press I started drilling and updrilling the 2 3/16th holes. | Photos Shop-Video |
| 1/11/2012 | Wing | W08 | W11-03 | W11-03 Wing Attach Blocks - Using the drill press I finnished drilling and updrilling the 2 3/16th holes. | Photos Shop-Video |
| 1/12/2012 | Wing | W08 | W11-03 W11-05 W11-02 | W11-03 Wing Attach Blocks - Pollished all sides to remove any cut or machine marks. Aligned W11-03 with W11-05 End Attach Angle and drilled the remaining 3/16th holes. W11-02 End Wing Attach Assembly - For one of the assemblies I used the drill press and drilled and updrilled the 1/4th holes for the two AN4-15A bolts. | Photos Shop-Video |
| 1/13/2012 | Wing | W08 | W11-02 | W11-02 End wing Attach Assembly - On further inspection of the assembly from yesterday I decided that the 1/4th holes for the AN4-15A bolts were not tight enough for the tight fit holes called for in the plans. The bolts are .246 and the holes appear to be the .25. I called and discussed this with Kerry at Sonex Tech Support. He said that what I did was OK but it would probably be better if I did them over. I ordered new material and smaller drill bit from Aircraft Spruce. | Photos Shop-Video |
| 1/14/2012 | Wing | W14 | W16-08 | W16-08 Gusset - Practiced how to make the bends correctly. | Photos Shop-Video |
| 1/15/2012 | Wing | W14 | W16-08 | W16-08 Gusset - Practiced how to make the bends correctly. | Photos Shop-Video |
| 1/16/2012 | Wing | W14 | W16-08 W16-07 | W16-07 and W16-08 Gussets - Used the brake to bend the 1/2in bend on the ends. Used a plastic tipped hammer to bend the 1/8th in bend on the sides | Photos Shop-Video |
| 1/17/2012 | Wing | W14 | W15-06 | W15-06 Gusset - Used the brake to bend the 1/2in bend on the ends. Used a plastic tipped hammer to bend the 1/8th in bend on the sides | Photos Shop-Video |
| 1/17/2012 | Wing | W14 | W15-07 | W15-07 Gusset - Used the brake to bend the 1/2in bend on the ends. Used a plastic tipped hammer to bend the 1/8th in bend on the sides | Photos Shop-Video |
| 1/18/2012 | Wing | W08 | W10-06 | W10-06 Tip Attach Angle - Cut two from Z01-03 Angle Stock. | Photos Shop-Video |
| 1/19/2012 | Wing | W14 | W14-02 -03 W11-03 -05 | W14-02 -03 Spacers - Used the band saw to cut the W14-02 Center Spacers from the .125 inch stock. Used snips to cut the W14-03 Web Spacers from .032 sheet stock. W11-03 Wing Attach Block - Used the band saw to cut out a new replacement Attach block. W11-05 End Attach Angle - Used the band saw to start cutting out the shape of a new replacement attach angle. See 1/13/2012. | Photos Shop-Video |
| 1/20/2012 | Wing | W08 | W11-05 | W11-05 End Attach Angle - Continued shaping the cut out. Did not turn out right. Cut out another using the band saw and belt sander. This one matched the shape and dimensions per the plan. | Photos Shop-Video |
| 1/23/2012 | Wing | W08 | W11-02 W11-03 W11-05 | "W11-03 Wing Attach Block - I used the drill press to drill and up drill the 3/16th holes per the plans on the new attach block. W11-02 End Wing Attach Assembly - I used the drill press to drill and up drill the holes for the assembly. I drilled the one 3/16th hole and the two tight fit holes for the AN7-15A bolts. I used a ""D"" bit for the finnal hole size for the two bolts. On one of the assemblies I then reemed out the hole just enough for the tight fit. Tomorrow I will do the other assembly." | Photos Shop-Video |
| 1/24/2012 | Wing | W08 | W11-02 | W11-02 End Wing Attach Assembly - Reemed out the holes on the other assembly. On both assemblies I installed the bolts and torqued them to 65 inch pounds. | Photos Shop-Video |
| 1/24/2012 | Wing | W08 | W11-06 | W11-06 Root Wing Attach Assembly - Finnished drill ing the holes on the two W11-03 Wing Attach Blocks. Using the Wing Attach blocks I located the holes on the W11-07 Root Attach Angle. Then using the drill press I started the holes. | Photos Shop-Video |
| 1/25/2012 | Wing | W08 | W11-06 W08-01R | W11-06 Root Wing Attach Assembly - Finnished drilling the the tight fit holes. I installed the AN4-15A bolts and torqued the bolts. W08-01R Right Main Spar Assembly - Drilled the holes and installed the MS24694-S56 and -S58 screws to attache the W11-02 End Wing Attach Assembly. | Photos Shop-Video |
| 1/26/2012 | Wing | W08 | W08-01R | W08-01R Right Hand Main Spar Assembly - I located the W11-06 Root Wing Attach Assembly using the location hole on the spar web. I drilled the holes and installed the 3 AN3-7A bolts and the 3 MS24694-S58 Screws per the plans and predrilled holes in the spar. Started locating the W20-02 Root Rib Attach Angle on the spar assembly. Decided to wait until tomorrow th start drilling holes. | Photos Shop-Video |
| 1/27/2012 | Wing | W08 | W08-01R | W08-01R Right Hand Main Spar Assembly - I installed the 8 AN3-7A bolts at the inboard end of the bottom spar cap. I riveted W10-06 Tip Attach Angle to the end of the spar on W10-07 Tip Web which was already on the pre assembled spar. For rib stations 1011 and 12 drilled holes in the spacers for the spar web. Clecoed the ribs in place to see what it will look like. | Photos Shop-Video |
| 1/28/2012 | Wing | W08 | W08-01R | W08-01R Right Hand Main Spar Assembly - I attached the W20-02 and W20-03 Root Rib Attach Angles to the spar assembly. I first located W20-02 and clamped in place. I then drilled the 1/8 pilot holes through the spar. Next I clecoed both W20-02 and W20-03 in place and updrilled to the 3/16th size holes. I installed the AN3-10A bolts washers and nuts per the plans. | Photos Shop-Video |
| 1/29/2012 | Wing | W08 | W08-01R | W08-01R Right Hand Main Spar Assembly - I attached W11-10R RH Tie Down Fitting and W11-11 Outboard Vertical Stiffiner Angle to the spar assembly. I located these parts by the predrillied holes in the upper and lower spar caps. I clamped the parts in place and drilled 5/32 holes to match the predrilled holes. I then clecoed these parts to the assembly. I then used the predrilled holes in the angle to locate the four holes in the spar web. I drilled those four holes with the #40 #30 and #21 drill bits. I also up drilled the hole in the upper spar cap using the #21 bit. I then updrilled the trhee holes in the lower spar cap using a 3/16th bit. The parts where removed and deburred. The parts where reattached using clecos. The two AN3-6A and one AN3-7A bolts where installed per the plans. I then used the Sonex bolt and hammer method to install the 5 rivets per the plans. | Photos Shop-Video |
| 1/30/2012 | Wing | W08 | W08-01L | W08-01L Left Hand Main Spar Assembly - I attached the W11-02 End Wing Attach Assembly. I installed the 8 AN3-7A bolts at the inboard end of the lower spar cap. I attached the W11-06 Root Wing Attach Assembly. I attached W20-02 and W20-03 Root Rib Attach Angles. | Photos Shop-Video |
| 1/31/2012 | Wing | W08 | W08-01L | W08-01L Left Hand Main Spar Assembly - I attached W11-10L LH Tie Down Fitting and W11-11 Outboard Vertical Stiffiner Angle to the spar assembly. I located these parts by the predrillied holes in the upper and lower spar caps. I clamped the parts in place and drilled 5/32 holes to match the predrilled holes. I then clecoed these parts to the assembly. I then used the predrilled holes in the angle to locate the four holes in the spar web. I drilled those four holes with the #40 #30 and #21 drill bits. I also up drilled the hole in the upper spar cap using the #21 bit. I then updrilled the three holes in the lower spar cap using a 3/16th bit. The parts where removed and deburred. The parts where reattached using clecos. The two AN3-6A and one AN3-7A bolts where installed per the plans. I then used the Sonex bolt and hammer method to install the 5 rivets per the plans. | Photos Shop-Video |
| 1/31/2012 | Wing | W08 | W08-01R W08-01L | Main Spar Assemblies Mating - I made three 3/32 pins to align the spars. I set the spars on 4 saw horses and used the pins to test the alignment. I found that a washer on one bolt on the left spar was not clear of the mating surfaces. I will move that washer to the other side. | Photos Shop-Video |
| 2/1/2012 | Wing | W08 | W08-01L | Main Spar Assemblies Mating - I reinstalled the bolt with the washer on the other side. | Photos Shop-Video |
| 2/1/2012 | Wing | W08 | W08-01R W08-01L | "Main Spar Assemblies Mating - I set the spars on 4 saw horses and used the three 3/32 pins to align the spars. I made two 3/16th pins and inserted them in the two wing attach block holes. I then clamped the spars together inplace. After verifying that there were no clearence problems and that the spars where aligned I updrilled the 5 holes to 1/4th inch. The three 3/32 holes were done 1/8 5/32 3/16 7/32 and 1/4th. I started with the center hole. After reaching 1/4th I inserted a AN4-10 bolt to help hold the location. The two attach block holes I first redrilled with 3/16th. The next larger 6"" drill bit I have is 1/4th so I went directly to the final size. I did use candle wax to lubricate the drill bit." | Photos Shop-Video |
| 2/1/2012 | Wing | W21 | W21-02 | W21-02R and -02L Right and Left Hand Bellcrank Pivot Assemblies - I started on the parts that go into these two assemblies. W21-10 Aileron Bellcrank Assembly. Drilled the 3/16th holes in the W21-11 Aileron Bellcrank Plate. Installed the AN3-14 bolts an Pivot Bushings per the plans. Made the two laminated phenolic spacer blocks W21-05 and W21-08. I placed the spacer blocks between the upper and lower angles and drilled the holes through the spacer blocks. | Photos Shop-Video |
| 2/2/2012 | Wing | W21 | W21-02 | I used the arbor press to press the bronze bushings into the upper and lower angles. | Photos Shop-Video |
| 2/4/2012 | Wing | W14 | W-15 W-16 | Today I drilled pilot holes in the spar web spacers for the right hand wing. I also clecoed the forward and aft ribs number 5 through 12 to the main spar for the right hand wing. I trimmed the aft number 5 rib per the plans. I trimed the forward and aft number 4 ribs per the plans and drilled the holes for the rivets for the gussets. | Photos Shop-Video |
| 2/6/2012 | Wing | W14 | W-15 W-16 | I finished attaching the gussets to forward and aft ribs number 4. I also trimmed forward and aft ribs number 2 and 3. I drilled the holes and riveted the gussets for ribs numbers 2 and 3. Ribs 2 3 and 4 were clecoed in place on the right wing main spar. | Photos Shop-Video |
| 2/7/2012 | Wing | W14 | W-15 W-16 | Cut the forward and aft ribs number 1 per the plans. Drilled and riveted gussets and W16-09 angle into place per the plans Clecoed number 1 forward and aft ribs to the main spar. I clecoed the right rear spar in place to check for fit. Tomorrow I will check all the ribs for the skin fit at both the main and rear spars. | Photos Shop-Video |
| 2/7/2012 | Wing | W21 | W21 | Today I received my 5/16 reamer. I line reamed the brass fittings and assembled the bellcranks. I used white lithium grease to lube the fittings. | Photos Shop-Video |
| 2/8/2012 | Wing | W14 | W14 W15 | "Worked on fitting forward ribs to the right main spar. Used the pre drilled holes to cleco the ribs to the right main spar. Then the flanges of the ribs do not align to the spar as shown in Detail ""K"" on drawing W14. On a couple of the ribs I drilled the holes with a #40 drill bit (which is slightly larger). This allowed the ribs to be aligned a little better." | Photos Shop-Video |
| 2/9/2012 | Wing | W14 | W14 W15 W16 | "Worked on fitting forward and aft ribs numbers 10 11 and 12 on the right main spar. Aligned the spars to fit as shown in Detail ""K"" of drawing W14. Clamped into place forward and aft rib individually and enlarged a couple of holes (#40) to match the spar holes. Then clecoed those holes and drilled remaining holes to match the spar holes (#40). Then clecoed and clamped both ribs in position and up drilled the holes to #30. Removed the clecos and check to be sure the holes were acceptable in shape and size." | Photos Shop-Video |
| 2/10/2012 | Wing | W14 | W14 W15 W16 | "Worked on fitting forward and aft ribs numbers 7 8 and 9 on the right main spar. Aligned the spars to fit as shown in Detail ""K"" of drawing W14. Made a template using a metal yard stick. Screwed the template to the side of the work table. Clamped into place on the spar the forward and aft rib individually and determined the needed alignment. Then clamped the ribs to the template with the appropriate adjustment and drilled the holes to match the spar holes (#40). Then clecoed both ribs in position and drilled the holes to #40 then 1/8th and then #30. Removed the clecos and check to be sure the holes were acceptable in shape and size." | Photos Shop-Video |
| 2/11/2012 | Wing | W14 | W14 W15 W16 | "Worked on fitting forward and aft ribs numbers 4 5 and 6 on the right main spar. Aligned the spars to fit as shown in Detail ""K"" of drawing W14. Clamped into place on the spar the forward and aft rib individually and determined the needed alignment. Then clamped the ribs to the template with the appropriate adjustment and drilled the holes to match the spar holes (#40). Then clecoed both ribs in position and drilled the holes to #40 then 1/8th and then #30. Removed the clecos and check to be sure the holes were acceptable in shape and size." | Photos Shop-Video |
| 2/12/2012 | Wing | W14 | W14 W15 W16 | "Worked on fitting forward and aft ribs numbers 1 2 and 3 on the right main spar. Aligned the spars to fit as shown in Detail ""K"" of drawing W14. Clamped into place on the spar the forward and aft rib individually and determined the needed alignment. Ribs 1 and 2 did not need any adjustment. For rib number 3 only the forward rib need a slight adjustment. Then clecoed both ribs in position and drilled the holes to #40 then 1/8th and then #30. Removed the clecos and check to be sure the holes were acceptable in shape and size. Also started fitting the rear spar for the right wing assembly." | Photos Shop-Video |
| 2/14/2012 | Wing | W21 | W14 W21 | W14 Wing Rib Installation - Finished fitting the rear spar to the right wing assembly. Updrilled all holes on the rear spar to #30 size. Removed the rear spar. Deburred all holes on the rear spar and aft ribs. W21 Aileron Bellcrank and Aft Rib #9 Assembly - Cut plastic shims for the Bellcrank Assemblies. I also cut -09 angles and marked the location for the pilot holes. Also cut to length -13 and -14 Fws and Aft Verical channels. | Photos Shop-Video |
| 2/15/2012 | Wing | W21 | W21 | W21-01R Wing Rib #9 Assembly - Today I drilled the pilot holes in the -09 Angles. I also drilled the pilot holes in the -13 and -14 Fwd and Aft Vertical Channels for the right hand rib #9 assembly. I then clamped -14 Aft Channel to the rib and drilled the #40 holes. After that I did the same for -13 Fwd Channel. I clamped -02R Right Hand Bellcrank Pivot Assembly to the rib and drilled the #40 holes. I located and drilled the #40 holes for one of the -09 Angles. | Photos Shop-Video |
| 2/16/2012 | Wing | W21 | W21 | W21-01R Wing Rib #9 Assembly - Today I finished drilling the #40 holes for the remaining -09 Angles. | Photos Shop-Video |
| 3/7/2012 | Wing | W21 | W21 | W21-01L Wing Rib #9 Assembly - Today I drilled the pilot holes in the -13 and -14 Fwd and Aft Vertical Channels for the left hand rib #9 assembly. I then clamped -14 Aft Channel to the rib and drilled the #40 holes. After that I did the same for -13 Fwd Channel. I clamped -02L Right Hand Bellcrank Pivot Assembly to the rib and drilled the #40 holes. I located and drilled the #40 holes for the -09 Angles. | Photos Shop-Video |
| 3/7/2012 | Wing | W23 | W23 | W23-08 Tubing Support Plate - Today I attached the tubing support plates to the forward ribs #1 thru #4 on the right wing. These will provide support and protection for the static and pitot lines running thru the wing. | Photos Shop-Video |
| 3/8/2012 | Wing | W14 | W14 | W14 Wing Rib Installation - Today I inspected the holes attaching the ribs to the main spar on the right hand wing. Due to some irregular shaped holes on ribs #9 and #10 I decided to updrill those holes to 5/32nd. All othe holes looked good / OK. | Photos Shop-Video |
| 3/9/2012 | Wing | W14 | W14 | W14 Wing Rib Installation - Clecoed all the ribs for the right hand wing to the main and rear spars. Ribs #1 through #12 are now ready to be riveted in place. | Photos Shop-Video |
| 3/10/2012 | Wing | W21 | W21 | W21-01L and -01R Wing Rib #9 Assembly - Today I adjusted the shims in the bellcrank assemblies to allow them to move more freely. I also updrilled all holes to the #30 size. I removed all clecos and deburred all the holes. I revited the angles to the forward and aft vertical channels. | Photos Shop-Video |
| 3/11/2012 | Wing | W17 | W17 | W17 Root Rib - Today I worked on making the Reinforcement Angles -02 through -09. I was able to complete 6 of the 8 angles. Using the band saw I cut the shape from Z02-03 angle stock. I then drilled the #40 pilot holes that were not common to the Root Attach angle. To make the notch that will go around the main spar cap I first drilled a hole in the corner. I then used the band saw to cut up to the hole. Finnally I used files to get the finnished shape. | Photos Shop-Video |
| 3/12/2012 | Wing | W17 | W17 | W17 Root Rib - Today I finnished making the remaining 2 reinforcement angles. I also discussed with Kerry at Sonex the sequence of when to install the Root Rib. He said to wait until after the wing box is squared and the aft skins are fitted. | Photos Shop-Video |
| 3/12/2012 | Wing | W17 | W17 | W17 Root Rib - For the right hand root ribs I used the band saw and cut off the flanges per the plans. I also cut out the area for the spar caps. | Photos Shop-Video |
| 3/13/2012 | Wing | W14 | W14 | W14 Wing Rib Installation - Today for the right hand wing I riveted ribs #1 through #12 to the Main and Rear Spars per the plans. I also finnished riveting the Bellcrank Assembly to Rib #9. | Photos Shop-Video |
| 3/14/2012 | Wing | W07 | W07 | W07 Wing Box - Today I made a brace out of angle. The brace is used to hold the ribs and spars square to one another. I also bent two brass rods to use as Plumb Bobs. I marked hole locations on the rear spar. Added blue lines for the ribs. I then clamped the upper aft skin to test locations. | Photos Shop-Video |
| 3/15/2012 | Wing | W07 | W07 | "W07 Wing Box - Today I first drilled out the rivets on the Root Rib angle on the rear spar. I did this so that I will be able to remove the angle when I install the root rib. Kerry at Sonex said to wait to install the root rib untill after the aft skins are fitted. Next I positioned the upper aft skin and drilled the #40 pilot holes for the row going into the rear spar. I made sure the edge of the skin and the edge of the rear spar were aligned. After that I made sure the frame was square. I located station 19"" on the main spar. Then using a square I made sure that it lined up with station 19"" on the rear spar. That station is where the bolt hole is located. Today I also started drilling the #40 pilot holes into the ribs. I lined up the ribs and made sure that there were not any edge issues." | Photos Shop-Video |
| 3/16/2012 | Wing | W07 | W07 | W07 Wing Box - Today I finished drilling the #40 pilot holes on the upper aft skin for the right wing. I did not yet drill the holes into the main spar. I also positioned the lower aft skin for the right wing and started drilling the #40 pilot holes. | Photos Shop-Video |
| 3/17/2012 | Wing | W07 | W07 | W07 Wing Box - Today I finished drilling the #40 pilot holes on the lower aft skin for the right wing. I also drilled some of the #40 pilot holes into the main spar for the upper aft skin. I also test fit the aft root rib. I will install it after I have finished drilling all the #40 pilot holes into the main spars. | Photos Shop-Video |
| 3/19/2012 | Wing | W07 | W07 | W07 Wing Box - I drilled every other #40 pilot hole in the lower atf skin at the main spar. | Photos Shop-Video |
| 3/20/2012 | Wing | W17 | W17 | W17 Aft Root Rib - Right Hand Wing | Photos Shop-Video |
| 3/20/2012 | Wing | W17 | W17 | W17 Aft Root Rib - Right Hand Wing - Fitted the aft rib behind the attach angles and clamped in place. I drilled a few holes for location. I then removed the angles and rib. I clecoed the rib to the angle in the correct position and drilled and updrilled the holes. I drilled the holes for -04 and -05 reinforcement angles. I then riveted all the parts for the aft root rib together. I then installed the aft rib by reinstalling the bolts and rivets that hold it in place on the wing. | Photos Shop-Video |
| 3/21/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - I drilled all the remaining #40 pilot holes in the main spar for the upper and lower aft skins. I also up drilled to #30 size many of the holes for both upper and lower aft skins. I did not up drill the rear and main spar row of holes. I also did not up drill where the root doubler will go. I also left a few rows near the main spar. I located the forward skin and drilled the #40 pilot holes for the upper portion of the forward skin. | Photos Shop-Video |
| 3/22/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - Turned the wing over so the bottom was facing up. Ran the poly tubing through the enlarged tool holes in the forward ribs. This will be used as a conduit for the wires for the wing tip lights. I then used the ratchet straps to pull the forward skin so the main spar holes would line up. Clecoed the main spar holes of the forward skin. I started drilling the #40 pilot holes from the main spar out toward the leading edge. | Photos Shop-Video |
| 3/24/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - Finished drilling the #40 pilot holes on the bottom forward skin. I also up drilled the bottom aft skin to the #30 size. | Photos Shop-Video |
| 3/24/2012 | Wing | W17 | W17 | W17 Root Rib Installation - Forward Root Rib Right Hand Wing - Fitted the forward rib behind the attach angle and clamped it in place. I drilled a few holes for location. I then removed the angle and rib. I clecoed the rib to the angle in the correct position and drilled and updrilled the holes. I drilled the holes for -02 and -03 reinforcement angles. I then riveted all the parts for the forward root rib together. I then installed the forward rib by reinstalling the bolts hold it in place on the wing. I drilled the #40 pilot holes trhough the forward skin and forward root rib and clecoed them together. | Photos Shop-Video |
| 3/25/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - Today I finished up drilling most of the holes on the bottom side of the wing. All the holes on the bottom skin overlap on the main spar were up drilled to #30. All the holes on the bottom forward skin were up drilled to #32 to allow for expansion of the hole when dimpled. | Photos Shop-Video |
| 3/26/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - I located and drilled the #40 pilot holes and up drilled #30 holes for the flap hinge. I attached the flap to the clecoed hinge to test the fit. | Photos Shop-Video |
| 3/27/2012 | Wing | W23 | W07 W23 | W07 Wing Box - Right Hand Wing - I fitted the Root Doubler and drilled the #40 pilot holes and up drilled to the final #30 holes. W23 Pitot Static Installation - I made the -05 Mounting Plate. I modified it to work with the Pitot Statis tube assembly I purchaed from Aircraft Spruce. This assembly was a recomended option by Sonex instead of the the plans assembly. I also located and cut the hole in the bottom forward skin for the assembly. | Photos Shop-Video |
| 3/28/2012 | Wing | W23 | W07 W23 | W07 Wing Box - Right Hand Wing - Deburred and dimpled the holes on the bottom forward skin. W23 Pitot Static Installation - Started installing the anchor nuts I was able to locate and drill holes for 2 of them. I needed order replacements for 2 more because 2 of the ones I had were not threaded right. | Photos Shop-Video |
| 3/29/2012 | Wing | W23 | W07 W23 | W07 Wing Box - Right Hand Wing - Deburred and dimpled the holes on the ribs for the bottom forward skin. I also located and drilled a hole in the bottom aft skin for the Tie Down Bolt. The hole will need to be enlarged to the out side size of the bolt after the skin is removed for deburring. W23 Pitot Static Installation - I was able to get one more anchor nut to work properly. I drilled the holes for the 3rd anchor nut. I then dimpled the skin and counter sank the anchor nuts for 3 of the 4 anchor nuts. I then riveted those 3 anchor nuts in place. | Photos Shop-Video |
| 3/30/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - Removed the bottom aft skin. I deburred the holes for the skin and the corresponding holes on the ribs main spar and aft spar. I enlarged the hole for the tie down bolt. I drilled the holes for wing skin cover plate. I also started putting the bottom aft skin back in place with clecos. | Photos Shop-Video |
| 3/31/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - I finished putting the bottom aft skin back in place with clecos. I pulled the bottom forward skin back in place using ratchet straps. I then clecoed the bottom forward skin in place. I turned the wing over. I finished up drilling all the holes on the top side. The aft skin was drilled to #30. The forward skin was drilled to #32. Along with updrilling the holes on the rear spar I located and drilled the holes for the hinge for aileron. | Photos Shop-Video |
| 4/2/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - Today I cut and trimmed the fiberglass tip to roughly fit. I will wait to do the final fitting and drilling utill after the wing is riveted. I also started debiring the top of the wing. I have debured the forward and aft skins. I have debured and cleaned the forward ribs. I have cleaned but not debured the aft ribs. I also installed the last anchor nut for the pitot attachement. I cut the tubing for the pitot and static lines. | Photos Shop-Video |
| 4/3/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - I finished deburring. I started dimpling the forward skin and ribs. | Photos Shop-Video |
| 4/4/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - I finished deburing the forward skin. I also re-installed the pitot static tubing. I also ran four wires through the wiring tube for the planned wing tip lights. | Photos Shop-Video |
| 4/4/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - Ron Smith (EAA Tech Counselor #1966) came by to look at the right wing before I started riveting the skins. He said all looked OK and go ahead and close up the wing. | Photos Shop-Video |
| 4/5/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - I re-assembled the wing using clecos. I then first riveted the top skins. I turned the wing box over and the riveted the bottom skins. | Photos Shop-Video |
| 4/7/2012 | Wing | W07 | W07 | W07 Wing Box - Right Hand Wing - Today I trimmed and drilled pilot holes (#40) for the fiber glass tip. | Photos Shop-Video |
| 4/9/2012 | Wing | W14 | W14 | W14 Wing Rib Installation - Left Hand Wing - Today I started work on the left hand wing. I finished fabricating the -02 and -03 spacers fpr the left hand wing. I started drilling the 3/32nd pilot holes for the spacers. I was able to drill the holes for the spacers for ribs #3 through #10. I clamped the spacers in place and used the pilot holes on the main spar to locate the spacer pilot holes. | Photos Shop-Video |
| 4/10/2012 | Wing | W14 | W14 | W14 Wing Rib Installation - Left Hand Wing - I finished drilling the #40 pilot holes for the spacers for ribs #11 and #12. | Photos Shop-Video |
| 4/10/2012 | Wing | W14 | W15 W16 | W15 Forward Ribs and W16 Aft Ribs - Left Hand Wing - I trimmed forward ribs #1 through #4 and Aft ribs #1 through #5 for clearance of main spar cap. I located and drilled both #40 pilot holes and #30 holes for the gussets on those ribs. I also started deburring and preping those ribs. | Photos Shop-Video |
| 4/11/2012 | Wing | W14 | W14 W15 W16 | W15 Forward Ribs and W16 Aft Ribs - Left Hand Wing - I finished deburing the ribs and gussets. I then riveted the gussets to the ribs. W14 Wing Rib Installation - I clecoed all the ribs (#1 through #12) to the main spar. | Photos Shop-Video |
| 4/12/2012 | Wing | W14 | W14 | W14 Wing Rib Installation - Left Hand Wing - I clecoed the rear spar to the ribs (#1 through #12). I up drilled all holes to #30 size. | Photos Shop-Video |
| 4/13/2012 | Wing | W14 | W14 | "W14 Wing Rib Installation - Left Hand Wing - I removed all the clecos and deburred all the holes on the ribs and spars. I enlarged the tool hole to 1/2"" holes in the forward ribs. This will be where I will run plastic tubing for the wing tip lights. I started riveting the forward and aft ribs to the main spar. I was able to rivet ribs #1 through #8." | Photos Shop-Video |
| 4/14/2012 | Wing | W14 | W14 | W14 Wing Rib Installation - Left Hand Wing - I finished riveting the forward and aft ribs to the main spar (ribs #9 through #12). I also assembled and riveted the bellcrank and rib #9 assembly. I riveted the rear spar to the aft ribs. | Photos Shop-Video |
| 4/14/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I squared and leveled the main spar and ribs. I also marked the rib stations on the rear and main spar on the upper side of the wing. I then started drilling the #40 pilot holes for the upper aft skin. | Photos Shop-Video |
| 4/15/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I marked reference lines on lower side of main and rear spar. The lines on the rear spar are lined up with the pilot holes drilled on the upper rear spar. This will aid in aligning the lower skin with the upper skin I also finished drilling most of the pilot holes for the upper aft skin. | Photos Shop-Video |
| 4/16/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I drilled every other pilot hole into the main spar for the upper aft skin. I finished drilling the pilot holes into the rear spar for the upper aft skin. | Photos Shop-Video |
| 4/16/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I drilled the pilot holes into the upper aft skin for the bellcrank uprights. I drilled every other pilot holes into the rear spar for the bottom aft skin. The reference lines on the rear and main spar align with the holes in the bottom aft skin. | Photos Shop-Video |
| 4/17/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I finished drilling the pilot holes for the bottom aft skin. I only drilled every other hole into the main spar for the bottom aft skin. | Photos Shop-Video |
| 4/18/2012 | Wing | W17 | W17 | W17 Root Rib Installation - Aft Root Rib Left Hand Wing - I trimmed the ends and notches per the plans. I clamped the rib in position and drilled as many pilot holes as could be reached. I then removed the bracket from the main spar an clecoed it to the rib. I finished drilling the pilot holes I clamped the reinforcement angles in place and drilled the pilot holes. | Photos Shop-Video |
| 4/19/2012 | Wing | W17 | W17 | W17 Root Rib Installation - Aft Root Rib Left Hand Wing - I corrected the reinforcement angles for the aft rib. I made new reinforcement angles for both aft and forward root ribs. I positioned the reinforcement angles drilled the holes and riveted the aft root rib. | Photos Shop-Video |
| 4/19/2012 | Wing | W07 | W07 | W07 Wing box - Left Hand Wing - I returned the root rib to its position. I drilled the pilot holes for the upper and lower aft skins into the aft root rib. I drilled all the remaining pilot holes for the main spar for both upper and lower aft skins. I up drilled to #30 holes for the lower aft skin except for both main and rear spars and the root doubler / wing walk. I unpacked the leading edge skin and clecoed it inplace at the upper main spar. | Photos Shop-Video |
| 4/20/2012 | Wing | W07 | W07 | W07 Wing Box - Left Wing - I drilled the #40 pilot holes into the forward ribs from the upper side of the leading edge skin. | Photos Shop-Video |
| 4/20/2012 | Wing | W17 | W07 W17 | W07 Wing Box - Left Wing - I filipped the wing over. I used ratchet straps to pull the leading edge skin into position. I clecoed the skin starting in the middle and worked out to the sides. I then drilled the #40 pilot holes into the forward ribs from the lower side of the leading edge skin. W17 Root Rib Installation - Forward Root Rib Left Hand Wing - I positioned the rib in place behind the attach angle on the main spar. I drilled a few locator pilot holes. I removed the attach angle from the main spar. I started drilling pilot holes through the Attach Angle Forward Rib and the Reinforcement Angles. | Photos Shop-Video |
| 4/21/2012 | Wing | W17 | W07 W17 | W17 Root Rib Installation Forward Root Rib Left Hand Wing - I up drilled all holes to #30 size. I deburred the parts and then riveted them together per the plans. I re installed the root ribs and attach angles in the wing box. W07 Wing Box - Left Hamd Wing - I then drilled #40 pilot holes into the forward root rib from the holes in the leading edge skin. I located and drilled #40 pilot holes through the flap hinge. I then up drilled (to #30 size) all the holes on the lower aft skin at the rear spar. | Photos Shop-Video |
| 4/22/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I clecoed into place the root doubler on the lower side of the wing. I then updrilled the holes to #30 size for the root doubler (lower skin side only). I up drilled to size #30 all the holes on the lower side into the main spar. | Photos Shop-Video |
| 4/23/2012 | Wing | W07 | W07 | "W07 Wing Box - Left Hand Wing - I up drilled the bottom leading edge skin holes to #32 size. I used the ratchet straps and removed the clecos on the bottom leading edge skin. This opens it up for deburring and dimpeling. I ran some 1/2"" tubing through the holes in the forward ribs. This is for wires for the tip lights." | Photos Shop-Video |
| 4/28/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I deburred all holes on the bottom side of the wing. I dimpled all the holes and ribs for the leading edge skin on the bottom side of the wing. I also installed the tie down eye bolt. I clecoed all the skins to the ribs and spars for the bottom side of the wing. | Photos Shop-Video |
| 4/29/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I turned the wing over so that the upper side is now up. I added the aileron hinge by drilling #40 pilot holes up drilling to # 30 holes and clecoing it into place. I also added the wing walk / root doubler by drilling #40 pilot holes up drilling to #30 holes and cleoing it in place. I up drilled all the holes at the main spar to the #30 size. I up drilled the holes on the leading edge skin that will be dimpled to the #32 size. All holes are now up drilled to their final size. | Photos Shop-Video |
| 4/30/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I removed all the clecos from the upper side of the wing. I debured the aft upper skin. I deburred the aft ribs rear spar and main spar. | Photos Shop-Video |
| 5/1/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - I deburred the upper forward ribs and upper leading edge skin. I dimpled the upper leading edge skin. I also deburred the wing walk / root doubler. | Photos Shop-Video |
| 5/2/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - Ron Smith (EAA Tech Counselor #1966) came by to look at the left wing before I started riveting the skins. He said all looked OK and go ahead and close up the wing. | Photos Shop-Video |
| 5/3/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - Clecoed the upper skins back on to the ribs and spars. Ran the wires for the wing tip lights through the plastic tube. Started riveting the upper aft skin at the rear spar. | Photos Shop-Video |
| 5/4/2012 | Wing | W07 | W07 | W07 Wing Box - Left Hand Wing - Riveted both upper and lower skins. All holes were riveted except for those where the Wing Walk / Root Doubler are located. Installed the cover plate on the bottom of the wing. Also cut and fit the fiberglass tip. Pilot holes were drilled for the fiberglass tip. | Photos Shop-Video |
| 5/5/2012 | Wing | W07 | Wing Lights | "Today I finished fitting the fiberglass tips. I cut a 2"" hole through the tip for wires and access for the tip lights. I located and drilled holes for the fiberglass Lotek pod to hold the tip lights. I attached the lights to the pods. I clecoed every thing in place. I did a temp hook up of the wires to a 12 volt battery to test the lights. They worked and look great!" | Photos Shop-Video |
| 10/20/2015 | Wing | W07 | Switched the prop bolts from AN5-40 to AN5-37. Installed the rivets holding the fiberglass wing tips to the wings. | Photos Shop-Video |