Skinning Left Wing - 8 Hours (71.5 Total)

Today I put the fabric on the left wing. This included prepping the wing. I installed the long aileron push/pull tube, flap teleflex, and select fuel lines. I used a 3' 5" fuel line for the rear fitting and a 14" fuel line on the front fitting. Since the middle fitting is accessible, I didn't bother connecting a fuel line to it. I used tarp repair tape (thick) as an anti-chafe tape on the bolt heads, tip wraps, wing tip gussets, and root rib edges. I tried several techniques for applying the tape to the bolt heads. The one I ended up with required me to cut a slit in the tape from the middle out. This allowed me to apply the tape in a cone shape. I also removed the overlap with my utility knife.

I attempted to skin the wing without any help. After several hours and only having 1/3 of the skin on, I had a friend come over and help. Within 30 minutes we had the skin within 12" of the root rib. I installed the first top rib which was easier than expected. Getting the skin the last twelve inches, to the edge of the root rib, was tedious. I was able to do it without the all-thread which is recommended but it required prying the root rib after the pan head screws were installed.

Heat Shrink Flap and Ailerons - 3 Hours (63.5 Total)

Today I finished de-wrinkling the ailerons and flaps. I used my clothing iron. I also started prepping the left wing for fabric. I noticed that the left tank has a straight fitting where is should have an angled fitting. I replaced the forward fitting with the correct type. I did not perform a leak test.

Heat Shrink Tail - 4 Hours (60.5 Total)

Today I used a heat gun to de-wrinkle all of the tail components. I also used a soldering iron to clean up any fraying fabric. I then wrapped the tail pieces in garbage bags to protect them from dust and dirt.

More Wing Construction - 3 Hours (56.5 Total)

Today I replaced the AN4-25ALP bolts which old the aft strut plate in place. The original bolts were too long. I ordered new bolts from Rans. I also attached the left fuel tank. I also attached hardware to the wing root transportation bracket.

Wing Transport Fixtures - 0.5 Hours (53.5 Total)

Today I verified that the left fuel tank is leak free. I also assembled my wing transporting fixtures.

Fuel Tank Fix - 0.5 Hours (53 Total)

Today I installed the new fuel tank fittings I received from Rans into the left fuel tank. I also plugged the fittings which were installed in the wrong locations with threaded stainless steel plugs.

This tanks had some type of residue inside it. Dish soap, gasoline, nor Simple Green worked at cleaning the tank. 409 did work.

I then leak tested the tank by filling it with hot water and letting it sit over night.

Fuel Tank Install - 5.5 Hours (52.5 Total)

Today I installed the fuel tank into the right wing. I also assembled most of the left wing.

Fuel Tank and Caps - 2.5 Hours (47 Total)

Today I verified that the right tank is leak free. Prior to this, I placed the fuel tank frame in the right wing. I need to let the fuel tank dry before I install it into the wing.

I also assembled the two fuel tank caps.

Fuel Tanks - 2 Hours (44.5 Total)

Bad day... Today I worked on the fuel tanks. I drilled and installed the fuel fittings correctly into the first tank but I incorrectly placed two of them in the left tank. I will probably need to order a new tank.

Wing Construction III - 3 Hours (42.5 Total)

Today I attached the tension top rib, alieron push/pull tube, and alieron push/pull tube guide.

Wing Construction II - 9 Hours (39.5 Total)

Today I rented an air pop rivet tool... which ended up working very well. I finished attaching the hardware to the leading edge and trailing edge spars. I also put together one of the wings. I still need to put the built-up rib on the first wing.

Wing Construction - 1 Hours (30.5 Total)

Today I started attaching the hardware to the leading edge spars of the wings. Unfortunately, the 3/16 stainless steel rivets are too much for my hand riveting tool. I will need to but a new tool.

Flaps and Ailerons Skinning - 5 Hours (29.5 Total)

Today I skinned the flaps and ailerons. The skins went on very easily but I did have problems with the tension ribs. The screw holes for the ribs did not line up with the holes in the flaps and aileron frames. I ended up reaming out the holes in the flaps and aileron frames to allow the screw holes to align.

Flaps and Ailerons - 1 Hours (24.5 Total)

Today I prepped the flaps and ailerons for skinning. This included drilling the hinge holes to proper size and riveting in the nut plates.

Retightening the Stabilizers - 2 Hours (23.5 Total)

Today I retightened the laces on the vertical and horizontal stabilizers. I didn't cut the strings in case I want to tighten them further.

Horizontal Stabilizer Skinning - 3 Hours (21.5 Total)

Today I skinned both horizontal stabilizers. While finishing up the second one, I realized that my tightening technique had improved and I should retighten the vertical stabilizer skin. My tightening technique included tying off one end of the rope as if it were finished then clamping or tying the other end to a weight to hold the slack. I then used two pairs of pliers to pull the rope taunt at each lace point. Letting the skin sit for a while in between repeated tightenings also improved the tightness.

Rudder and Elevator Skinning - 3.5 Hours (18.5 Total)

I skinned the second elevator which wasn't any easier than the first. The skins seem to need to be stretched. This was done by fighting with it!

I also skinned the rudder today. The lacing method made the job much easier. Because I didn't want the lacing rope over the sharp edges of the aft gusset, I stopped lacing just before getting there. This made the skin near the gusset less taunt. The square knots recommended didn't hold so I used several knots back to back.

Skinning Rudder and Elevators - 5 hours (15 Total)

@#$%! Putting the skins on the rudder and elevators is a pain in the ass! I ended up breaking two of the rudder braces. I didn't relies they had already snapped into place so when I continued hammering on them, the notched ends tore off. I used tarp repair tape to hold the braces in place but at an angle from the buttons (washers) as I inserted the frame into the fabric. A slight angle works best. I scratched up the leading spar and trailing edge of the rudder by forcing the ends to pop into place.

The elevators were worse! I broke one of the center braces but because it was too long in the first place, I was able to salvage it. I ended up mauling the end caps by trying to force the frame over the compression fitting. I removed the end caps from the second elevator so I wouldn't damage them.

Stabilizers, Rudder, and Elevators - 1.5 Hours (10 Total)

Today I finished fabricating the internal braces for the stabilizers, rudder, and elevator. I also trimmed the cleaned up the edges of the plastic ribs used in the stabilizers. My bench grinder worked well for this but it did make quite a mess.

Rudder and Elevators - 3.5 hours (8.5 Total)

Today I framed the rudder and elevators. I also fabricated most of the internal braces for the stabilizers, rudder, and elevators out of the 0.5 inch raw stock.