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Archive for the ‘Pushrods’ Category

Right Flap Pushod Hole, Elevator Pushrods – 4.5 hrs

January 7, 2012 Leave a comment

Saturday Jan 7, 2011

Today I made a little paper template of the flap pushrod cutout in the left side of the fuselage and transferred the pattern to the right side to speed the cutout process. I did not directly match the left hole however. I first cut the right hole undersize compared to the left side and then used the actual pushrod on the right side to finish enlarging the cutout. That was just in case the geometry on both sides did not match. It still saved me time. Here is the finished cutout from the side.

Here is a view from the inside looking down.

Then I started preparing the parts for the elevator pushrods. There are two of these; a small one that goes from the control columns to the bellcrank, and a large one that goes from the bellcrank to the elevators. I cut the tubes to length and deburred the edges of the parts. I also aligned one fitting on the small pushrod but stopped there when I decided it was time to prime the insides of the tubes. The instructions say to let the primer dry thoroughly so I plan to let these sit overnight.

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Riveting the Right Leading Edge – 3 hrs

January 22, 2011 Leave a comment

Saturday Jan 22, 2010

Today I riveted most of the right leading edge structure together. Did not have a helper but I was able to buck all but three or four rivets along each rib solo. I’ll need a helper to shoot the rest.

Right Leading Edge Riveted (mostly)

I also reinstalled the fittings on the two small aileron pushrods. This was kind of a pain because the rivets are long a tricky to shoot. My squeezer won’t work on them because the rivets are so long. When I bucked them with the straight set the rivets want to bend over so you have to be really careful. I had to drill out one rivet and shoot it again. After successfully bucking these I cleaned the surface with a little MEK and brushed on a light coating of EkoPrime because there was some bare metal showing.

Reinstalled aileron fittings

I stopped by Aircraft Spruce today and picked up a few things; another quart of EkoPrime, some Aeroshell 7 grease for the aileron bellcranks, a tube of EZ Turn (aka fuel lube) for the fuel drain fittings, and some AN316-6 jam nuts because my kit was one short.

Categories: Leading Edges, Pushrods, Wings

Redo on the Aileron Pushrods – 1 hr

January 21, 2011 Leave a comment

Friday Jan 21, 2011

Well I’ve been out of town for a few days so there has been a short lull in the building progress. But I had some excitement while gone. I was at Vandenberg Air Force Base helping prepare the Glory satellite for launch on Feb 23 if all goes as planned. I had a role in building the aerosol polarimeter on the satellite and we are performing final inspections before launch. I happened to be there when a large rocket was launched on base and had a chance to see it lift off from about 5 miles away. Very cool!

While I was gone it occurred to me that there was something I forgot to do when assembling the small aileron pushrods. I forgot to prime the inside of the tubes. Dang! So I tonight I removed the two rivets on one end of each pushrod and coated the inside of the tube with primer. I thinned the Stewart Systems primer with distilled water to make it easier to get 100% coverage on the inside. I’ll reassembly the tubes later this weekend when the primer is good and dry.

Fitting removed to prime the interior of the tubes

I also had one rivet on the left leading edge that was bugging me. The rivet had leaned over a little and was probably OK but I decided to drill it out and replace it. I couldn’t live with it. Instead of bucking a new rivet I decided to use a LP4-3 pop rivet instead. Many builders use these for all the leading edge to spar rivets so the strength of the LP4-3 rivet is no issue. The rivet in question is the one on the far right in this picture. No new progress tonight but I feel better now.

Replaced a leaning rivet with a pop rivet

Categories: Leading Edges, Pushrods, Wings

Primed and Dimpled Left Wing Top Skins – 4 hrs

January 16, 2011 Leave a comment

Weather was great again today so it was a good time to prime the left wing top skins. For some reason I did this in a odd order. First I dimpled the inboard section as you can see below. Normally I would have done the scotch-brite job on the surfaces to be primed first because if you do it after it is easy to enlarge the dimple holes if you get a little too aggressive with the scotch-brite.

Dimpling the left inboard top skin

So I ran the scotch-brite carefully over the interior surfaces along the rib lines and the entire area where the wing walk doubler overlaps and then set up the paint gun to prime the surfaces. This time I just used a few pieces of cardboard to mask off the surface I did not want primed. Then I realized I did not dimple the outboard section so after the primer cured in the sun a while I dimpled it with a little help from my daughter Jessica.

Getting some help dimpling the outboard top skin

Then I cleco’d the skins to the wing skeleton to set up to shoot rivets.

But just for fun I made the two smaller aileron pushrods. This means cutting the tubing to length, pressing in the end fittings, cross drilling for rivets, and bucking two rivets on each end. This didn’t take too long.

Aileron control pushrods

Categories: Pushrods, Skins, Wings

Right Tank Sealed Up – 5 hrs

January 1, 2011 Leave a comment

Saturday Jan 1, 2011

The major accomplishment today was sealing up the right fuel tank. That includes installing the access cover and the fuel level sender. My days of messing with ProSeal are hopefully coming to a conclusion. Yea! Here is the tank with the fuel sender and access cover installed and sealed up.

Right fuel tank sealed up

The primer was cured on the inside of the aileron pushrods so I put in the end fittings and drilled six equally spaced holes on each end for the rivets. I wrapped a strip of paper around the tube and marked off the circumference. Then I divided that distance into six equal segments and marked that on the paper. Then I wrapped the paper around the tube again and transferred the spacing to the tube. Then I just drilled the holes 1/4 inch from the end of the tube using the drill press.

Pushrods drilled

Then I installed the MSP-42 pop rivets wet with primer.

Pushrods riveted

Next I finished constructing a poor man’s paint booth out of 1×2’s and plastic sheeting. It’s not sealed so its only good for light work on small parts but it will keep me from getting spray onto nearby stuff in the garage.

El cheapo paint booth

Categories: Fuel Tanks, Pushrods, Wings

Pitot Mast Mounting – 3 hrs

December 31, 2010 7 comments

Friday Dec 31, 2010

Happy New Year!

I did some puttering around in the shop today. Not too focused since it’s new years eve. And I spent some time cleaning up the garage. It gets to be a mess very quickly.

I think I finally decided where I will mount the pitot tube mast. It will be one bay outboard from the tiedown ring and near the outboard rib. That is where Roee Kalinsky out his using the Dynon AOA pitot and it looks like it works well. It should be far enough away from the tiedown ring that the chains should never hit it.

To align the mast to the wing skin I first started by clamping the mast to the spar in the desired location. Then I made a small L-bracket that I plan to use to tie the mast to the outboard rib for extra strength and stiffness.

Locating the Pitot Mast

Once I verified that the bracket fits I removed the top skin and taped the mast cut-out template onto the spar such that it is aligned with the mast.

Taping on the template for cutting the hole

The I put the bottom skin on and taped the template to the skin without moving it. Then I removed the tape to the spar.

Put the bottom skin on and tape the template to it

When I took the bottom skin back off the spar the template came with it aligned to the desired location. Now I just need the guts to cut a hole in my precious wing skin.

I also primed the interior of the large pushrod tubes . The plans say to pour in primer and swish it around or spray it. I put in a few ounces of EkoPrime but it doesn’t swish. It just runs. I had to use more primer than expected to get very bit of the interior covered. I caught the excess running out of the other end with a plastic cup. The problem is the primer is way thicker than it needs to be. It’s just a little extra weight and that’s OK but I couldn’t put the end fittings in. So I removed a half inch or so of primer at each end so the fittings would fit. Next time I will thin the primer as much as I can with distilled water to make it flow better and lay down thinner.

Removing primer from the inside of the pushrod tubes

But I don’t want the surface bare so I re-applied a very thin coat in those areas with a Q-tip.

A very light coat reapplied

Countersinking Right Main Spar for Skins – 3 hrs

December 30, 2010 Leave a comment

Thursday Dec 30, 2010

Today I finished countersinking the right wing main spar for all the skin dimples. This is tedious and just takes time. Here is another shot of the sea of holes that must be machine countersunk. This was before I put a dab of primer on each countersink with a Q-tip.

Way too many holes!

This is a shot of one of the “orphan rivets”, right in the middle of the picture. I call them that because the plans don’t address them. There are about six holes in each side of the spar that align with the ribs but they will be covered by the tank skins. You have to rivet these now before installing the skins or never.

Orphan rivets

I came up with an easy way to clean ProSeal off of clecos. Rather than soak each one and wipe the ProSeal off with a paper towel I put them into a large mason jar and add an inch or so of MEK or Toluene and shake it up for a while. The agitation washes the sealant off of the clecos and it settles to the bottom after a while. Works pretty good.

Cleco washing machine

I was craving a little change of pace after working on the skins and tanks for so long so I decided to measure and cut the aileron pushrods to length. These are cut out of a 12 foot long piece of raw stock. I found that the fittings are to large in diameter to slip into the ends of the tube easily. I’ll have to research what to do about that.

Aileron push rod tubes

Categories: Main Spars, Pushrods, Wings