04-21-03 2.0 Hours

Well the wings, or should I say wing parts finally arrived!!! By Fed X Freight. As we unloaded the boxes from the truck the driver noticed the end of the spar box was punched through. We pulled the end of the box off and inspected. Everything seemed ok but I still had him call in and report the box damage and record it on the shipping invoice.

I opened the spar box and thank God there was no damage. Once I had the boxes open I found places to store the parts. There is definitely a lot of parts. (Wing arrival photos)

04-26-03 2.5 Hours

Took Inventory and organized all components. Bins work very well for this.
Worked on wing jig. I will be doing both wings at the same time.

04-27-03 1.0 Hour

Countersunk nutplate attach holes in 1st. spar.

04-27-03 1.0 Hour

Riveted nutplates on 1st spar.

05-5-03 0.5 Hour

Countersunk nutplate attach holes in 2nd. spar.

05-11-03 3.0 Hours

Fabricated tie down brackets, deburred, cleaned and alodined.

05-13-03 3.5 Hours

Sized Bell crank bushings and Bell cranks. Honed for good, free fit of bushing. Installed W-933 tie down bracket and the WD421-R Bell crank. Leave the bushing .015/.030 longer than the bell crank. This will allow the bell crank to move on the bushing and gives .015/.030 of vertical play. Also, it took a few good looks at drawing #9 to figure that the WD421-R (right) Bell crank goes on the left spar. Go figure?

05-17-03 4.0 Hours

Installed left bell crank assembly. Deburred rear spars and doublers.

05-19-03 2.0 Hours

Drilled and deburred left rear spar and W907E and D. Enlarged aileron push rod tube holes.

05-21-03 2.0 Hours

Drilled and deburred right rear spar and W907E and D. Enlarged aileron push rod tube holes.

05-23-03 2.0 Hours

Matched drilled rear spar and 907C & B doublers and deburred. Drilled #40 holes in top of rear spars in area where 907C & B go and dimpled. Due to lack of room after the 907C & B are riveted into place.

Due to the time it takes to maintain this site I will be doing things just a little different. Instead of links to photos embedded in the text I will create a photos section page that will contain thumb nails to the larger photos to save some time. I will also include text in the larger photos when I feel it is needed or I have the time to do it.

06-09-03 4.0 Hours
Inventoried Fuselage and Finishing kit.

06-12-03 1.5 Hours
Matched drilled Ribs and Spars left wing.

06-13-03 2.0 Hours
Deburred Ribs left wing.

06-14-03 4.0 Hours
Deburred Ribs left and right wing.

06-17-03 3.0 Hours
Deburred lightening holes.

06-18-03 2.0 Hours
Deburred Ribs some more.

06-20-03 1.5 Hours
Deburred Flap and Aileron Brackets.

06-22-03 6.0 Hours
Deburred Flap and aileron brackets. Fabricated A914 stops. Clecoed and matched drilled Aileron brackets. Matched drilled Aileron brackets to rear spar.( Did this prior to prime and Assy. of rear spar.) Fabricated the W925B and C's. Matched drilled W925 brackets and the W911 and W910. Matched drilled the 925 Assy to the outboardW911 and W910 inboard ribs and rear spar. ( Leaving center flap bracket until later when skins on on.

06-23-03 2.0 Hours
Matched drilled flap gap faring to rear spar left wing and Aileron gap faring.

06-24-03 2.0 Hours
Fabricated and matched drilled flap brackets, right wing. ( Only fabed brackets for center flap bracket rib #7. It will be drilled in place later.

06-26-03 4.5 Hours
Finished drilling right wing flap brackets. Matched drilled flap and aileron gap fairing. Deburred brackets. Countersunk #40 on the rear spars where the doubler plates are underneath. Dimpled the 3 holes on the outboard end of the rear spar for outboard rib. Deburred rear spars. Deburred ribs and red wheeled to remove scratches. Also, used scotchbrite Loc wheels and a die grinder to deburr with. Worked Great!

07-5-03 1.0 Hours
Drilled .750 hole in ribs for electrical.

07-6-03 1.5 Hours
Metal preped, washed and Alodined ribs.

07-7-03 2.0 Hours
Primed ribs.

07-8-03 to 07-10-03 4.0 Hours
Assembled rear spar and ribs with aileron brackets and flap outboard& inboard brackets. Left out mid bracket for now.

07-12-03 3.0 Hours
Riveted left ribs and rear spar to main spar.

08-02-03 2.0 Hours
Riveted ribs to right main spar.

08-05-03 1.5 Hours
Finished match drilling bottom left skins and removed skin.

08-09-03 5.0 Hours
Matched drilled left leading edge. Put ribs in L. fuel tank. Finished splice strip.

08-21-03 1.0 Hours
Fab left and right tank stiffners& drilled. Made W932-DG

08-23-03 2.0 Hours
Made the T912 brackets. Drilled 1/8 & 3/16 holes, clecoed and blind riveted the 912's to the tank and mounted the tank to the wing.

08-24-03 2.5 Hours
Drilled 3/16 holes through the spar into the 912's. Drilled splice and checked twist. Less than .020. Removed brackets to deburr.

08-27-03 1.0 Hours
Started countersinking left tank 901-902 span of rivet holes.

08-30-03 3.0 Hours
Finished countersinking 901-902 holes in the left tank. Drilled #19 holes in 901 splice strip.

09-03-03 1.0 Hours
Worked on fabricating the T905 and starting drilling the T912 for nutplates.

09-05-03 1.5 Hours
Finished fabricating T905L.

09-07-03 4.0 Hours
Drilled T905 and reinforcement T410's. Flycut tank ends and drilled mounting flanges. Drilled and dimpled T903 end ribs. Attached nutplates to T407 ring.

09-11-03 1.0 Hours
Removed all clecos from left wing and removed skins.

09-19-03 1.5 Hours
Clecoed ribs to right leading edge. Clecoed to R spar. Started putting ribs in R tank.

10-06-03 2.0 Hours
Drilled L leading edge ribs to main spar. Had forgot to do this. Matched drilled R top skins to ribs and spars.

10-11-03 1.2 Hours
Matched drilled skins. Matched drilled w919 strip to L.E.

10-20-03 2.5 Hours
Finished match drilling R Tank. Drilled tank brackets to the T902 Baffle. Matched drilled tank and T912 to R main spar.

11-30-03 4.0 Hours
Finished fabricating T905R and drilled to IB rib. Drilled T410's. Drilled T407 ring and countersunk. Dimpled T903 end rib and riveted nutplates.

12-01-03 1.0 Hours
Countersunk spar to skin rivet holes.

12-14-03 8.0 Hours
Deburring and dimpling wing skins.

12-15-03 1.5 Hours
Deburring and dimpling wing skins.

12-16-03 2.0 Hours
Deburring wing skins.

12-19-03 1.5 Hours
Deburred wing skins and tank ribs.

12-20-03 6.0 Hours
Deburred and dimpled skins and ribs.

12-21-03 6.0 Hours
Deburred and dimpled LE skins, bottom wing skins and countersunk L main spar.

12-24-03 to 12-31-04 15.0 Hours
Dimpled splice strips. Riveted on nutplates. Washed, alodined and primed LE components and skins. Riveted L LE together and clecoed to Main spar.

01-03-04 5.0 Hours
Riveted L LE to main spar. Finished L LE. Riveted R LE together and clecoed to R main spar.

01-04-04 to 1-16-04 4.0 Hours
Deburred and dimpled tank skins.

01-13-04 2.0 Hours
Drilled R. Finished match drilling R Tank. Drilled tank brackets to the T902 Baffle. Matched drilled tank and T912 to R main spar. Finished fabricating T905R and drilled to IB rib. Drilled T410's. Drilled T407 ring and countersunk. Dimpled T903 end rib and riveted nutplates. Finished match drilling R Tank. Drilled tank brackets to the T902 Baffle. Matched drilled tank and T912 to R main spar. Finished match drilling R Tank. Drilled tank brackets to the T902 Baffle. Matched drilled tank and T912 to R main spar. Finished match drilling R Tank. Drilled tank brackets to the T902 Baffle. Matched drilled tank and T912 to R main spar. Finished match drilling R Tank. Drilled tank brackets to the T902 Baffle. Matched drilled tank and T912 to R main spar.

01-17-04 5.0 Hours
Riveted and sealed L tank ribs, all but end ribs.

01-18-04 3.5 Hours
Riveted and sealed L. tank end ribs, T905 bracket and reinforcement plate.

01-22-04 2.5 Hours
While waiting on tool, started L&R ailerons.

01-26-04 2.0 Hours
Assembled L. tank access plate, Fittings and vent line.

01-31-04 3.5 Hours
Finished sealing L. tank.

02-01-04 2.0 Hours
Dimpled R. tank skin and cleaned parts.

02-02-04 3.0 Hours
Sealed fuel sender L. tank. Riveted stiffeners , drain and cap flange R. tank.

02-03-04 1.0 Hours
Pressure tested tank using compressed air and soapy water. No leads found.

02-05-04 1.0 Hours
Mounted L. tank

02-06-04 1.0 Hours
With Joshua's help, started riveting left top I.B. skin

02-07-04 2.0 Hours
Made the W918 control rods.

02-08-04 2.0 Hours
Made the w917 control rods.

02-16-04 1.0 Hours
Riveted L. top skin.

02-17-04 2.5 Hours
Riveted L. top skin.

02-22-04 2.0 Hours
Riveted top left skins.

02-25-04 2.5 Hours
Sealed and riveted R. tank.

02-27-04 2.0 Hours
Sealed and riveted R. tank.

02-28-04 2.5 Hours
Sealed and riveted R. tank.

03-06-04 2.5 Hours
Installed vent line and Assembled pickup tube(Vans). Installed and sealed cover plate.

03-07-04 4.5 Hours
Mounted sender and adjusted. Sealed and closed tank baffle. Riveted tank mounting brackets. Cleaned a couple hundred clecos. Note: I think my countersinks were not deep enough on some holes. Had some high rivets.

03-13-04 5.0 HoursInstalled fuel sender R. tank. Riveted R. leading edge rib. * Joshua shot the rivets and I bucked. He did a great job! Squeezed L.E. skin to spar rivets. Leak tested R. tank- no leaks. Cleaned and primed tank ext. areas. Mounted tank.

03-20-04 4.0 Hours
Finished installing tank screws. Primed R wing top skins. Clecoed skins to spar and ribs.

03-21-04 2.5 Hours
Match drilled stiffeners to left aileron skins and started to dimple skins.

03-23-04 2.0 Hours
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03-27-04 7.0 Hours
Made flap/aileron table out of MDF and 2x4s. Shaved high rivets on r-tank. Dimpled L aileron skins. Dimpled stiffeners. Cleaned parts for prime. Primed skins and stiffeners. Back riveted stiffeners to skins. Clecoed bottom skin on and matched drilled to 905LR. Deburred and dimpled skin and 905R&L bottom. Assembled w/ 2 rivets in 905L/R and flipped the assembly over. Clecoed nose skin to Bottom and flipped back over. Clecoed nose to top spar and skin. Top skin at this point looked very wavy! Made sand bags out of cement (dry) and freezer bags and used a ½ x 3 board to evenly distribute the 4 bags. Total weight was aprox. 45 lbs. Drilled nose ribs and counterbalance tube. Placed AEX wedge in T.E., drilled and clecoed to table.

03-30-04 1.0 Hours
Deburring aileron parts.

04-02-04 2.0 Hours
Dimpled nose ribs and 905LR. Countersunk AEX wedge. Dimpled TE of top and bottom skins and spar row.

04-03-04 4.0 Hours
Scotch brite ribs, spar, doubler plates, etc. Cleaned and primed parts. Riveted frame assembly. Riveted skins on to spar and ribs. Tank sealant on T.E. and clecoed to flap table to cure.

04-06-04 1.0 Hours
Riveted trailing edge. Assembled hinges and torqued nuts.

04-09-04 1.5 Hours
Deburred r- aileron parts and skins.

04-10-04 1.0 Hours
Clecoed r-aileron frame and drilled counterbalance tube.

04-11-04 1.0 Hours
Dimpled skins and stiffeners.

04-17-04 3.0 Hours
Riveted stiffeners onto skins. Started to match drill bottom skins to 905LR and noticed that the spar and skin holes didn't line up. I dimpled the wrong side of the bottom skin and now it's reversed. Drilled out stiffeners to use again. Scrapped skin. Will order new one. Started left flap. De- plastic parts, straightened 908 spacers and frap brackets. Clecoed to spar and matched drilled.

04-18-04 1.0 Hours

04-19-04 2.5 Hours

04-20-04 2.5 Hours

04-22-04 1.5 Hours

04-26-04 1.0 Hours

05-09-04 1.0 Hours

05-11-04 3.5 Hours

05-13-04 8.0 Hours

05-15-04 3.0 Hours

05-16-04 1.5 Hours

05-17-04 2.0 Hours

05-25-04 3.5 Hours

05-27-04 3.5 Hours

06-05-04 3.0 Hours

06-08-04 1.5 Hours

06-09-04 1.5 Hours

06-11-04 3.0 Hours

06-12-04 3.5 Hours

06-13-04 1.5 Hours

06-15-04 1.5 Hours

06-16-04 4.0 Hours

06-19-04 1.0 Hours

06-21-04 1.0 Hours

06-23-04 0.5 Hours

06-25-04 1.0 Hours

06-26-04 1.0 Hours

06-28-04 2.0 Hours

07-17-04 2.5 Hours

07-18-04 1.0 Hours

07-20-04 5.5 Hours Total Hours 308.2