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  #51  
Old 09-03-2017, 10:30 AM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Los Angeles
Posts: 372
Default Small Steps are Still Progress

As the wing build continues, no real drama. The leading edges went on without much trouble; not nearly with the difficulty I envisioned from reading other blogs. As it turned out, most of the leading edge to spar rivets were reachable with the squeezer. I only had to drive about 10% of them, and of those only 5 on the right wing were blind and needed two people. I used a short double offset and taped it to the gun so it wouldn't rotate.


For the splice strip between the tank and the outer leading edge skin, I tweaked the nut plates to better conform to the skin using a vise and some scrap brackets. This worked out well.



After installing the tanks, I noticed the skin thicknesses aren't all the same. Some are 25 mils , others are 32 mils. I wish I would have beveled the skins before assembly to make this transition smoother, but maybe there will be a chance to smooth the 7 mil step before paint.


I started riveting the skins on with my resident engineer-in-training. I am still trying to work out the best technique. I tried the long offset back rivet tool, but this takes so much umph on the gun the rivet heads aren't pretty; acceptable, but not pretty. So we tried the normal method as in the picture. This worked out well for the ribs, but still looking for a better method for the skin to spar rivets.
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John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for thier use.

Extra dues paid 2018, worth every penny

RV9A- Status: tail feathers done less tips
Wings 90%
www.pilotjohnsrv9.blogspot.com

Last edited by PilotjohnS : 09-03-2017 at 10:38 AM.
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  #52  
Old 09-22-2017, 10:10 AM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Los Angeles
Posts: 372
Default Top Wing Skins

Look no clecos! A few of the rear spar rivets are still not in near the root; it seems these will be easier to squeeze once the wings are out of the build stands.

The easiest way I found to do this was from the trailing edge. Starting with the center rib of each skin, I would rivet the skin to the rear spar between the two center ribs. Then work up from the trailing edge on each rib. I could just reach the fourth rivet above the J stringer by laying on a creeper.

[IMG][/IMG]

After each skin was done on the lower portion, I would then corral a helper and rivet each rib the rest of the way up and then the main spar. I found a helper with a tungsten bucking bar was the easiest. I also used a wi fi endoscope camera hooked to my iPad so I could see around the other side and validate each rivet as we went. For $40 on amazon, the endoscope camera was well worth it. After a while, my friend would understand a good rivet and we would move along.





I took advantage of my rivet buddy not wanting to go home (because of traffic, not the wife, so he said) and was able to get all the top rivets on the right wing too. The rest I can get from the bottom with a creeper.



The wing is going slower than I anticipated, but I am taking my time and keeping the quality up.
After checking the twist, everything is as before. I did notice the right skin had to be cleco'd in a certain order to get all the holes to line up, so I ended up clecoing the skins on twice and using a cleco in every hole. There must have been some sag the first time. I am glad I didn't start riveting until both skins were on and fully cleco'd in place.

(Wow the shop is a mess!)
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Thank you
John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for thier use.

Extra dues paid 2018, worth every penny

RV9A- Status: tail feathers done less tips
Wings 90%
www.pilotjohnsrv9.blogspot.com

Last edited by PilotjohnS : 09-22-2017 at 10:13 AM.
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  #53  
Old 11-17-2017, 06:31 PM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Los Angeles
Posts: 372
Default Flap and Aileron Brackets

Making steady progress on the wings. Everything pretty much to plan. One note: the instructions were written long before the extra aileron brace was engineered. So the instructions say to install the aileron brackets before the flap brackets. This build order needs to flip around now. The flap brackets need to be installed prior to the aileron brackets since the extra reinforcing interferes with the rivets as seen in the picture below.



One thing to note, the bottom skin rivets can still be accessed with this brace in place; on the RV7, I believe the brace interferes with the skin rivets, not a problem on this RV9.

Moving on now with the flaps and ailerons...
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Thank you
John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for thier use.

Extra dues paid 2018, worth every penny

RV9A- Status: tail feathers done less tips
Wings 90%
www.pilotjohnsrv9.blogspot.com

Last edited by PilotjohnS : 12-24-2017 at 12:15 PM.
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  #54  
Old 12-24-2017, 12:14 PM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Los Angeles
Posts: 372
Default The End (of the Wing) is Near

The end is near, both of 2017 and this wing build.

The ailerons are finished, and I am quite happy with the results. One aileron trailing edge is dead straight, the second took a little work to get out a very minor ripple; I think the ripple was caused by not riveting the trailing edge together as soon as the pro-seal was dry and letting the trailing edge sit unclamped for a few days. No worries should be fine.

I think the secret to building ailerons with no twist is the leading edge straightness. I spent a little extra time making sure the bottom skin was absolutely flat from the stainless steel leading edge weight to the spar. Since drilling the leading edge is very difficult due to the super hard stainless steel, I ended up having some extra "lightening" holes in the stainless steel bar. During final assembly, I made sure the leading edge ribs sat flat on my super flat surface plate (granite kitchen counter top). Once the leading edge is riveted to the spar, the aileron becomes enormously stiff. I am glad I took the extra time to make this part perfect.



For the trailing edge drilling, I make a simple metal guide; should have done this long ago.



I am currently working on the flaps and planning out the internal stuff that needs to go in before the bottom skins are on. I am thinking I will fully install the heated AoA pitot tube, and the autopilot servo for the future G3x panel. I am planning the magnetometer for the right wing tip and the VOR antenna for the left. So my present plan is to not pull any wires for those until the tips go on in a year or two. The wings already have conduit for the wiring, so pulling the wires should be easy.
As for the lights, I saw some new Baja Design that seem choice, but with the pace of technology, still not sure if I will install now.
__________________
Thank you
John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for thier use.

Extra dues paid 2018, worth every penny

RV9A- Status: tail feathers done less tips
Wings 90%
www.pilotjohnsrv9.blogspot.com

Last edited by PilotjohnS : 12-24-2017 at 02:29 PM.
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  #55  
Old 12-24-2017, 01:51 PM
rv9av8tr's Avatar
rv9av8tr rv9av8tr is offline
 
Join Date: Dec 2006
Location: Portland, OR
Posts: 821
Default

Looking good! I put Xponder and APRS antennas in one wing tip and NAV/Marker Beacon in the other. The magnetometers went on the Horizontal Stab platform just in front of the Vert Stab. Have had no issues with the arrangement. Merry Christmas..... and yes, get the QB Fuselage!!
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