Sunday, September 7, 2014

Right Wing Aft Rib Prep

There are 14 aft ribs that will need to be deburred, smoothed, scuffed, straighten and fluted. Each one takes about a hour of hand work to accomplish this task, its mindless work but it has to be done.



Once I complete the deburring and smoothing the edges, the special tool that I built works really well in getting the flanges bent to 90 degrees.


A quick check with the combination square verifies that the flange is 90 to the surface of the rib.


Flutes are place between each hole the take the curve out of the part. Note the gap between the rib and table to the left of the fluting pliers.


Once both flanges are fluted the rib lays flat against the table top. The last step is to Cleco the ribs to the front and rear Spars so that the pre-punched holes can be drilled to size.




Total time this session, 12 hours.

Build Meter: 421 hours.



Sunday, August 31, 2014

Right Wing Rib Conduit Access

Vans gives the builder three options as too running the electrical wires and coaxial cables out to the tips for lights and antennas. After looking at other builders site I am going with flexible nylon conduit which will be installed in a access hole that will need to be drilled in each rib. 

Although there are no dimensions on the cut sheet showing where this hole is drilled, I laid out the hole from a few measurements from the bottom and front flange.


Below the first of many conduit access holes is drilled. Based on this hole all other ribs will have the the 3/4" hole drill in this same location. Once the one was complete I fastened to the wood jig two rails based on the leading edge and bottom flanges of the rib. 

That way by clamping each rib down to the wood jig aligning it with the two edges each hole should be in the same location. This will only apply to the ribs with left flanges, another jig will be made for the ribs with right flanges.



Since there are right and left flange ribs a jig is needed for each. Once I had the wood cut and trimmed so it would fit on the inside of the rib, and the rib will fit over the jig I aligned the unibit and then added three rails to the underside of the jig to fit around the drill press table and clamped them in place and then nailed them to the underside.


The right hand flange ribs are drilled with the unibit once the jig is in place and clamped down and the rib are clamed to the wood fixture so all the 3/4" conduit holes are drilled in the same place on each rib.


The remaining aft ribs have had the conduit access drilled and will be deburring, the edges smoothed, scuffed, and fluted. After which all will be Clecoed to the front and rear right wing Spars. 



Total time this session, 7 hours.

Build Meter: 409 hours.

Wednesday, August 20, 2014

Right Wing Leading Edge

Once I completed prepping the leading edge ribs, I removed the blue film from the inside of the right leading edge skin and placed the skin in the wooden frame to aid in getting the ribs Clecoed to skin. Once all ribs but one were in placed, I removed the unit from the frame.



The rib that goes on the end will get installed once the wing is place on the wing stand as it will match up with the end rib on the fuel tank.


I took the time to fasten the leading edge to the Spar just to see how everything will fit together.



I made a note to myself that once the wings are in the stand, which I have not started building, I will need many more 3/32" Cleco's if I am to assemble both wings at the same time.




Total time this session, 10 hours.

Build Meter: 402 hours.


Sunday, August 17, 2014

Fuel Tank Prefab

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Total time this session, 20 hours.

Build Meter: 392 hours.


Saturday, August 2, 2014

Fuel Tank Rib Prep

The first task I did was to seperate the leading edge ribs into two left and right wing stacks. Once that was complete I removed the fuel tank ribs from each stack labeled them, and set them aside.


The aft ribs were next to get separated, and labeled and placed back on the rack. Each rib will need to be edged, smoothed, deburred, and fluted, a large task that will take some time to complete.


I started with the fuel tank ribs and will finish the right side before going on to the left tank.


The task of preping each rib takes time to complete. Over the course of a few days, one or ribs each time, I was able to get them completed. 


One of the task each rib will need is the flanges to be straightened so that they will be 90 degrees to the surface. During my research on the stage of the build, I saw a simple fixture that would aid in this task. From the detailed material list it took no time to construct it from scrap material. This link will take you the detailed material list and construction sequence. http://www.rv7-factory.com/?p=1096


The angle of the 2x4 is cut at 11 degrees and the handle is cut to 22 degress. This allows the flange to be pinched past 90 so when it springs back the end result is right on.


All flanges are bent using the fixture and checked with a square to verify the flange is perpendicular to the rib. The last step is to flute the flanges to take the warp out of the ribs.


Total time this session, 25 hours.

Build Meter: 372 hours.


Tuesday, July 22, 2014

Rear Spar Prep and Assembly

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Total time this session, 18 hours.

Build Meter: 347 hours.