Monday, March 12, 2018

March 10/11 Update: Right wing systems

Right wing fuel tank tested, "passed", re-installed on the wing.  All bolts torqued and screws in place.

Started installing wing wiring harnesses and conduit: I'm going to run enough wiring through this conduit to support either GMU-22 or GMU-11 magnetometer: my current plan is to install GMU-22 in left wing in the position provided by Vans.  If this proves to be problematic I'll switch plans, and will have wiring in place. 

Tuesday, March 6, 2018

March 6 Update - QB wing, right

I had only a couple of days at to work since the last post:  since then I've removed the fuel tank from the right wing and installed the fuel sender.   As with prior wing I had to modify the bend of the sender float arm.  I also found the resistance to up-down movement of the arm to be more "stiff" than I'd like.  I found the identical part (It's a Stewart Warner automotive style sender) on Summit Racing (where I buy primer) used it - resistance is just right.

I used my Amazon-bought endoscopic camera ( ) to check position of float in the "up-down" directions.

Then used sealant per KAI to final-install the sender. 

Sunday, February 25, 2018

February 25, 2018 Update

This update is about a week late.  Since last weekend, nothing has happened thanks to work related travel.   After I finished the first trail fitting of wingtips and installing the wingtip rib, I did an initial install.  The wing tip trailing edges were too high and top side of the wingtip didn't match aileron outside edge in neutral aileron position (using template tool to do this).  It took me a while to figure this out:  I had carefully checked alignment before drilling the wingtip ribs and again before riveting them.  After discussing with Vic, I determined that I needed to split the aft edge of wingtip, re-fit rib (ordered a new one of course), and use epoxy/flox to re-fit it all.

This worked well and now I just need to final install wingtip (after sanding down the sealed original rivet holes etc).

I've moved left wing back into the wing cradle and right wing to work surface to start the wing process all over again.  I'll start with fuel tank and simultaneously do wiring, aileron/flap gap seals, etc as time permits.

Sunday, February 11, 2018

February 11, 2018 Update

Working on wingtip.   Trimmed to fit, match-drilled to wing skins.  Test fitted the wingtip rib.  Also confirmed that wingtip matches up to aileron.

Installed wingtip strobe/position light (AeroLEDS).

Then drilled skin holes to #27, deburred, dimpled.

Drilled wingtip holes to 27, then using nutplate jig, drilled for nutplates, countersunk holes (#40 and #27).   Installed 1/2 of nutplates.

Very productive day.

February 10, 2018 Update: Completed Pitot install, starting on wingtips.

I have completed all wiring and plumbing installation on the pitot/AOA tube, and now starting on wingtips.  Fitted lens before trimming wingtip and starting install onto wing.

Tuesday, February 6, 2018

Update February 6th: Bottom wing skins riveted, Pitot tube installation

Since last post, I've ordered a Garmin heated pitot/AOA (regulated).  I decided to make a change based on advice from Vic (from unregulated).  This required adding a single 22ga wire to the power wires already in place.  Easy to do this with the conduit in place.

I've fitted the pitot tube to the mast, trimmed and shaped the aluminum tubes in the pitot, completed wiring setup for the pitot, and drilled the access plate to fit the control box with wires.  Also continued to tidy up wiring in the wing.

Completed prep of wing bottom skin (deburr, dimple, scuff, prime) and test fitted skin and fittings.  While testing the skin and pitot mount fit, I wasn't happy with the mating of the pitot mast base and the angle support (riveted to adjacent rib): the matchup wasn't perfect and rather than resting on the full angle, the mast support was just touching a portion of it.  I decided to make a "shim" rather than re-fit the angle.  I mixed up some epoxy/flox, waxed the back of the pitot base, and clecoed the entire structure together.  The flox mixture filled the gap pefectly: after curing, the support came right off the "shim" and now rests fully on the "matched" angle support (now shimmed to match up perfectly).  (forgot to take a photo of this...).  I decided to drill the one rivet that uses this support out to 1/8 and used a Cherrymax rivet - a standard rivet would have to be very long and it would be hard to buck. 

Yesterday completed the riveting of the bottom skin.  Today final install of pitot tube.

Thursday, January 18, 2018

January 18th Update

Got quite a bit done.  First, I've been cleaning up wiring, putting shrink wrap over wires where they might chafe, adding cable ties, just making it look super/extra tidy.

Next, torqued all the bolts in the aileron controls, and checked torque on bolts in aft ribs through spar.

Today I started prep of the outboard bottom wing skin and fitted the Dynon pitot mast to the spar, adjacent rib, and skin.  I'll be doing "all Garmin G3X" and Garmin pitot tube, but Stein Air recommended the Dynon mast - it comes with a nice kit, good instructions (I had to look them up on the web but they're good!).   I match drilled the bracket to the spar flange, then match drilled holes in skin and bracket using the template.  I'm putting the pitot/AOA tube one bay outboard of the aileron brackets based on Vic Syracuse's recommendation.   Easy to reach from outboard access panel, and clears the aileron pushrod tube/brackets etc.

Dynon has a nice template to help match up the mast to the skin - the most time was removing material carefully, smoothing the edges, and repeatedly checking fit.  I'm very pleased with the result.  The pitot mast includes an angle brace which I riveted to the adjacent rib: this really stabilizes the installation.  I've seen people attach pitot masts to access hatches but I wouldn't be comfortable with the stability of that - the plus side is access and easy of replacement of course.

Next steps will be countersinking the mast bracket, finishing skin prep (including dimpling) and fabricating the J-channel stiffener.  The RV-14 instructions are TERRIBLE in giving any guidance on how to do this on a quickbuild wing.  I spoke with a Van's support person (Eric) who pointed me to the RV-10 instructions (page 20-5) which tell you how to do this on QB wings.  The only difference is length of course, which I found in section 16.  The fun never ends!