Started March 2, 2010 Build Time 34 Hours
Looks like this could be another one of those sections that will test your patience. Well, off I go.
Gathered all the wing ribs and sorted them out, there are three different types - W-1010, W-1011 and W-1012. First these must be straightened and fluted. I found that the after section only needed to be fluted and not much cause the bow was quite small.
It was then time to fabricate support bracket for the torque tube support. A simple process and just takes time. Once completed attached torque tube support, the fabricated spacer and fabricated angle along with the VA-146 Flange bearing. Match drilled all the holes clecoing as I went. Ready to be prepped and primed then set aside for now.
Then moved on to clecoing on the flap hinge rib and the flap hinge bracket to 2 of the W-1010 and W-1011 wing ribs (did them all since I am building both wings at the same time) and match drilled all the holes into the flap bracket and the wing rib. Did this also to the wing most inner wing ribs that have the torque tube supports on them.
It mentions to trim some of the flange on one of the wing ribs for each wing, W-1011. When I first did this was not paying much attention and took the ribs that I just match drilled the flap hinge brackets and removed those flange pieces. Found out soon after that this was supposed to be done to the other W-1011 wing ribs. Have new ones ordered from Vans second day air.
While I was ordering, decide I was going to add the electric aileron trim to my build so that was is also on its way.
I then attached all the wing ribs to the wing spars with cleco's. Match drilled all the #12 holes in the upper and lower attach points of the forward most flange of the wing ribs. Once completed moved on to match drill all the #30 holes in the same flange. Next match drilled the #40 holes in the upper and lower rib tabs and the flanges of the main spar.
When the wing ribs are attached, I went back and checked the direction and made sure that each wing ribs was correct. Good thing as two of them needed to be moved around.
Since all wing ribs are now clecoed in their respective position, I took them off one by one, deburred, preped and primed each one as I went so that I knew that would be going back in the exact same spot as I first attached them. Just before re-attaching each rib, I drilled the bottom of each to 3/4 inch for the conduit for wire runs instead of inserting the bushings. Also drilled and inserted the bushings for the pitot line.
All wing ribs have been put in place and riveted to the wing spar. I inserted the rivets into the holes and to make sure that I did not ruin the alodine on the rivets, I covered each one up with tape. This worked our really good, the only problem was getting off the blue tape from the head of the rivet.
One other thing that was a major improvement to the riveting process was the Tungsten bucking bar I purchased. Yes they are expensive at $130 for a small block and contemplated whether it was worth it or not, but now I know. One of the best purchases I have made for tools.