Finishing Wing Riveting

January 1st, 5h

Today, we finished the wing skin riveting.

First, we fixed the little dent in the left leading edge following Vans instructions by forming a piece of wood to fill the leading edge from the inside and using a mallet, carefully fixing the dent.  Then, we finished the last panels of riveting in the left wing.

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Afterward, we moved on to riveting the plate nuts for all the access panels.

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Access pannels

December 22nd, 4h

The wings are very close to complete, just few items left.  So, I decided to install the  the access panels, so that I can close the wings:

  • Match drilling access panels to wing bottom kin
  • Match drilling access panels to planetenuts
  • deburing
  • dimpling
  • Priming

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What left is to rivet the platenuts to the bottom Skins, then to screw the access panels

Riveting Bottom skin

November 30th,  December 1st, 14h

We continued on riveting the bottom skin for the right wing.  We nearly finished the whole bottom skin, at the exception of the last 2 raws. We ended up having a little incident, dropping the bucking bar inside, we decided to check with Vans before continued.

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Then we moved on to the left wing and riveted the whole left bottom wing skin. As well, we finalized the pitot tube installation.

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Before closing in the wing.  We took pictures of the serial number of the hardware inside.

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Riveting Bottom skin

November 24nd, 6h

After some more reading and talking with Vans about riveting the bottom skins and attaching the flaps,  I realized that I had to setup the flaps first.  So I had to remove all the previous rivets I set in the bottom skin.  Then after setting up the flaps.  We riveted the bottom inner skin and half of the bottom outer skin for the left wing

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Riveting Bottom Skins

November 3nd, 5h

 

The wing internals are nearly complete. So, it is time to start riveting the bottom skins.  First we start with fitting the skins.  The is a very small gap, about 1mm between the bottom skin and the fuel tank skin in the left wing.  It does not look concerning.

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Then we moved on to the riveting.  We started with the most inner ribs, working in an L shape, but access is pretty bad, with not much visibility.  After a bunch of trials, we decided to break for the time being, and continue this on a fresh day.

Wings Riveting & Tie Down Continue

June 5th & 9th 6h

In order to install the tie down rings, I needed to tap the tie down assembly, which went on pretty smoothly.

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Then, we continues on riveting the left wing leading edge to the main spar.  We continued using solid rivets.  Again access here is hard, but we made it work with 2 people.

We riveted all of the ribs, but the holes in the outboard rib turned to be too close to the flange, making access to the rivets very bad.  We tried riveting couple of those rivets, but the results were not good, so we are replacing those rivets and we are looking to modify the rivet tool or find some custom rivet tool for this rib.

 

Riveting wings

May 26th, 27th,  11h

We continued on riveting the wing top skins:

  • We finished riveted W702 Left
  • We riveted W703 Left
  • We riveted W703 Right
  • We riveted W703 Right

All went on very smoothly and the results looked great. The fit between the leading edge and W703 for both wings is great.

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Then we moved on to riveting the leading edge ribs to the main spar.  We modified a pop rivet gun so that it can fit is tight quarters.  Then we tried to rivet, the rivet gun broke!  Then we decided to go back to buck riveting, trying to be as dexterous as possible in reaching all the rivets.  It was not that bad at the end.  It took a lot of effort, but we got the right wing done with solid rivets, which are way more structurally rigid than pop rivet.

We decided to leave the rivet of the leading edge ribs to the main spar for the left wing to another day.

So, we move on to installing the conduit.  This was time consuming and took a lot of effort, giving that the conduit diameter is larger than the diameter of the hole.  This is done by design to achieve close highness.  I did half of the conduit for each wing and the results look good.

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