September 2007 Archives
The spacing, drilling, deburring and dimpling of the left Wing skin/Gap seal is completed.
This is the opposite side view.
Same prep and methods as for the Right wing, as usual it goes along so much faster. 2" spacing is required although the equal division results in a 1/4" discrepancy. So per Van's build manual, this is 'lost' within 4 holes being 1/16" smaller between each of the holes.
This is the top skin view. Finally finished this fairly tense stage. The image makes the skin look very scratched, it is not like that without the flash effect though. Who say's the camera does not lie?
Before the W-814 can be fitted the wing skin and the seal needs to be dimpled. The face is a very important part of the build.....no honest, honest!!!
Et Voila! Let's hope it's not a cock up!
The Gap Seal is now positioned just prior to back drilling through to the skin. The process to get this far has taken ages for what is about to be achieved, if only it had been pre punched!
The plans call for a 2" rivet spacing for the W-824 and the wing skin. Having measured up and pre drilled I will then use the W-824 as a 'jig' to back drill through to the skin. Can't afford a mistake here.
Builders Tip! Always have the die pin pointing upwards, then manually place the female end of the die above and keep it held flat, then and only then wack it with a dead blow hammer.
This method ensures the skin doesnt buckle upwards and avoids a figure of eight shape whole if the skin moves very slightly.
Having deburred all the holes on both sides, now using the Avery tool to dimple sking after removing the plastic film with a gas torch.
After removing the QB Rib rivets on the rear spar, the W-814 sits correctly and relaxed against the wing skin with the 6/32" edge. Now match drilled to the ribs only.
Aligning the W-824 prior to match drilling. It's very important to clamp this item properly as if not precisely positioned it will pull the trailing wing edge down and distort the final result.
View from beneath the W-413 showing the set rivets.
Note: the 'bottom' rivet is to be an AN426 countersunk rivet per the plans.
Although it looks as if I could have fitted this without trimming, in fact it is not possible as the various rivets fall precisely along or above the bend line of the W-824 flange. This is a real pain to keep trimming and will need to be finessed once the W-824 flange is flush with the rear spar after removing some rib rivets.
The revised system is much better with the most recent kits.
Go on son, squeeze that Mother!
Van's do not including fitting instructions on this pre pre punched version of the W-824. I called technical support at Van's and spoke with Joe Blank. "Just trim the part to fit, yeah, it's a little unclear but you'll work it out soon enough" So this what I've done.
Drilled outboard side of Aileron bracket and then matched drill to rib.
Spot the mistake? Used all AN470 rivets instead of 1 AN426 (countersunk), will pick this up later.
This image is from below and looking 'up' at the rivet line. The proximity of the rivets to the rib was pointed out to 'Joe Blank' at Van's who said " Yeah, it's gonna be tight but that's the way it is" I volunteered to 'trim' the rib flange a little but he said it would probably turn out OK. He was correct, it just clears the flange. Also, the off line is as a result of the QB, not me!!! Although it looks significant it's actually about 3/32" as it's exaggerated by the zoom effect. HONEST!
Riveting the W-414 (L) to the rear spar using the 4" yoked hand squeezer. Just makes it!!!
View from beneath using an extended length set.
Now with the wing trailing edge and the flap brace flange aligned not the bending of the wing 'downwards'. This will have an effect later when it comes to aligning the flaps with the fuselage and also a 'spring' effect with the flap hinge. To be continued......
This image illustrates the lower inboard wing trailing edge and the Flap Brace clecoed to the rear spar in it's relaxed state. Note: the misalignment is approx 1/4" on an inch at the root end.
Problem? The flap brace is only partially pre punched from Van's. The rear spar is pre punched to marry up the two parts, however, in this relaxed state you can observe a substantial mis alignment. This is a known problem with Van's and they do have a fix, but only when the builder has not picked up the error and riveted the whole thing together! I will try and see what can be done prior to that stage!
After deburring all the match drilled holes, time to dimple using the hand squeezer, including the rear spar.
More of the same. Image shows rear spar partially dimpled.
Ribs and now rear spar being dimpled using the hand squeezer. Van's suggest to dimple the rear spar and then a gentle hand counter sink to seat skin dimple only.
Ribs and rear spar match drilled per the Left wing process. Center rib deburred, dimpled and ready to prime etc.
Square on view of rib center lines marked up and ready for match drilling.
Marked up ribs. Outboard view
Right wing ribs marked up with rib centerlines prior to match drilling.
