Feb 13, 2002  3 hours

I started on the right tank tonight.  I have followed the build sequence as presented in the plans as closely as possible throughout this building process.  Tonight, I decided to deviate from the build sequence as described in the plans.  I visit other builder sites to get ideas on how they have approached different tasks and Steve Hurlbut described a build sequence for the initial assembly of the tanks that makes sense to me.  I gather from Steve's site that he had followed the plans build sequence and didn't like the results.  After reading the plans, the statement that the leading edge skin and the tank skin should be "perfect, elongate the skin holes if necessary" provided the needed nudge to try something a little different.  I'm a builder that likes to see things and drill things in place whenever possible.  I don't trust my measurements especially when as little as 1/32 off in a couple places would require elongating skin holes.  The plans call for measuring and drilling holes in the center of the flanges on both sides of the 7 "Z" brackets.  My take on this was dead center.  I'm not that accurate.  So here's my path, the idea stolen from Steve.  I'll update if I run into problems.

First step is to drill an 1/8th hole in the center of one flange on each "Z" bracket.  I've found that with minimal effort, one can sometimes create a jig that helps in these repetitive processes without having to measure each individual piece.  Or in my case, use the measurement as a check point.  I took a 2X4, drove a nail to use as the stop, centered the first "Z" bracket in the drill press and clamped the jig in place to be used to do all the remainder.IM000329.jpg (34709 bytes)

Next cleco the "Z" brackets to the baffle.  I drew a line down the center of the flanges, again as a check point.  I then used a square and the center line to align the "Z" brackets to the baffle.  Drill all 5 holes in the "Z" bracket and baffle.IM000330.jpg (64275 bytes)

Cleco all the ribs to the baffle and "Z" brackets.IM000331.jpg (47835 bytes)

Next I clecoed the leading edge skin (or top side) to the ribs and baffle.  It would not matter which side you clecoed on, I just knew that on my wings the bottom skins were already off so this way would give me more visibility.IM000333.jpg (42020 bytes)

At this point you can place the assemble on the spar and align with the rear leading edge skin before drilling the "Z" brackets to the spar. IM000334.JPG (73019 bytes)  IM000335.jpg (49441 bytes)

It's late and will be continued tomorrow.  Again, the point of doing this in this sequence is to allow you to drill one flange of the "Z" bracket with the assemble in place.  I will drill the "Z" brackets from the bottom side of the spar.

Feb 14, 2002  1 hour

I slipped away and drilled the "Z" flange from the bottom of the spar.  This really did work out well.  It was no problem to drill these with the bottom skins off.  One additional thing going for me was that my most inboard main ribs were backordered so they haven't been installed on the main spar yet.  This allowed me to get to the most inboard "Z" bracket without having to battle between two wing spars.   IM000338.jpg (19376 bytes)

Feb 15, 2002  2 hours

Attached the nut plates to the "Z" brackets and three nut plates on the spar.  Started re-assembling the tank.

Feb 16, 2002  7 hours

Fabricated all the tank stiffeners. IM000345.jpg (40004 bytes) Drilled all the stiffeners to the right tank. IM000346.jpg (45966 bytes) I placed the tank back on the spar and after one last verifying that everything was aligned, I final drilled the holes in the tank _ leading edge brace.

Next was assembling the rib to the skin and final drilling the holes in the skin through the ribs.  IM000347.jpg (40246 bytes)

I fabricated the T-405 bracket. While I was at it I went ahead and fabricated the left one as well. It took a long time to fabricate the first one and only a few minutes for the second one. IM000349.jpg (30528 bytes) I'm not sure if these are small enough. It doesn't look like there is enough room for the head of the rivets that go through the skin and ribs.  We'll see.

IM000351.jpg (18101 bytes)

 

 

Feb 18, 2002  4.5 hours

Worked on the interior ribs today.  I did not have a fly wheel cutter and needed to cut out the access hole in the interior rib.  I went to a 3 hardware stores and finally found one that I thought would "sort of" work.  I did a little modification to the fly wheel cutter and then cut the access holes in the ribs.  It worked much better than I thought it would.  Next was to clean up the cover plates for the access hole.  I drilled the holes, deburred, dimpled & coutersunk where needed. IM000352.jpg (45494 bytes)  Riveted the plate nuts in place on both the left and right interior ribs.  (I'm actively working on the right wing but where fabrication is involved, I'm doing the left as well.)  Fabricated the anti-rotation brackets for the fuel line. IM000354.jpg (67288 bytes) Thinking about changing one tank to a flop tube. 

Drilled the filler cap in place and the drain plug in the right wing.  I made the clip for both tanks to hold the vent line in place and drilled the hole in the interior ribs for the vent line to pass through the interior web.IM000355.JPG (75019 bytes)

Probably go back to the wing spar to deburr & finish leading edge next.  I'm waiting on the tank dimple dies, sealant and the left leading edge skin.