July 30th, 9h
I continued on the installation of the roll servo and tie down. First I attached the tie down to both the left and right wing, with all new hardware, setting all the torques correctly with the new torque wrench. Then I installed the roll servo into the right wing. Afterwards, I moved on to attaching the bellcranck, and I discovered that Vans forgot to ship me the bell crank bushings, so I ordered them. Then I moved on to the wiring, but I did not have the proper crimping tool, so I ordered one.
July 13th, 14th, 16th and 23rd, 12h
To get started in the roll servo, I needed to first fix the tie down assembly that was over torqued. So, I removed the tie down for both the left and the right wings, removed all the platenuts by removing all the rivets. Then riveted new plate nuts. Then primed. Afterwards, I will be re-attaching the tiedown with new hardware.
Then I moved on to the assembly of the roll servo. I decided to attach the limiting bracket, to ensure that the servo will never get into the null space, which will cause loss of roll authority. Then I assembled the rest of the hardware, which went pretty smoothly. Next is to attach the roll servo with the tie-down into the wings.
July 6th, 10th 18h
I finalized by decision on the avionics and decide to go with Dynon. So, I got all the part for the wing: heated pitot probe with AoA, servo for aileron and magnetometer.
I got started by the pitot probe. First I had to pick a place for the pitot probe. The option shown in the plans by Van does not work for the Dynon pitot probe because it will lead to interference between the aileron bell-crank and the pitot tube. I decided to put the pitot probe just to the left of the bell-crank assembly, to avoid interference while still being as close as possible to the center, between wing root and tip.
Then, I mounted the pitot tube mast into the wing by cutting out the mast slot in the wing skin, and drilling the attachment holes in the mast and the wing skin. As well, I drilled the bracket that attaches the mast to the rib and the skin to support the required loads.
Then I installed the pitot probe, which fits pretty well into the mast. I drilled 4 holes for #6-32 screws to attached the the pitot to the mast.
As well, I attached the pitot heat controller into the rib, right under the pitot tube, so that I don’t need to add any extension to the wires. The wires provided were more than plenty to reach between the pitot and the controller.
Then I moved on to the plumbing:
- I attached the wires between the pitot tube and the controller.
- I fluted the aluminum tubing for both the pitot and AoA.
- I connected the pitot and AoA aluminum tubing to the plastic tubing
- I past the plastic tubing through the tooling holes. The bushing provided were made for a 3/8inch holes, but my tooling holes are 5/8inch, so I need to buy some new bushings.
June 30th 2h
Installing the aileron brackets was a little tricky because of access. With two people we were able to get into all the bolt and nuts and set the torque values.
June 14th 3h
The next part to solder together was the control board. The soldering went on pretty smoothly.
June 30th 5h
I decided to go wit the flyLED wing tip lights. These light include all of the navigation, landing and taxi light in the wing tip. So, no need to cut the leading edges to install landing and taxi lights. I do have a little bit of concern about the lighting of the center of the runway, but I read that the lights are plenty. If not, an option is to add and extra light under the prop to light the center of the runway.
So, we got started today in the lights, by soldering all the part together and testing. All the LEDs work and the lights are very bright, even when using just 9V, instead of the 12V that will be used in the plane.
June 29rd, 30th 12h
We tackled all the flap riveting for all parts for both the left and the right flap over the weekend. It was a bit tricky to rivet the ribs to the top skin, but we were able to go through it. The final results look great.
June 23rd, 24th, 25th, 27th 16h
I continued on with the prep of both the left and the right flaps:
- finishing the fabrication of the inboard angles.
- counter sinking the bottom of the back spar
- removing the vynil
The flaps are ready to be riveted.
June 19th, 20th, 6h
I got started on the flaps, the last big part of the wings. The flaps look straight forward and the preparation is going pretty smoothly:
- clekoed the skeletons and skins.
- fabricated spacers for the edge ribs.
- fabricated shims for the back of the ribs.
- drilled the skeleton and skin.
- fabricated the inboard angles.
The flaps are looking good: