Wednesday, May 22, 2013

Completed Structure Overview (655.25hrs)

I completed another part so it's time for an update to the big picture. I'm leaving the Fuel Tanks as "in work" until they get tested, so those are still highlighted red. I finished the ailerons so those turned blue. And I'm starting on the flaps, so I went ahead and highlighted those as "in work".

655.25 hrs Total Time Building
  214.75 hrs of the total belong to the Wings (includes tank time)
     75.25 hrs solely to the Fuel Tanks
     25.5 hrs solely to the Ailerons
  440.5 hrs is a mixture of tail and fuselage, both still have work to be done on them

 As always blue is completed and red is in work.

Monday, May 20, 2013

Finished Ailerons

A productive weekend leaves me feeling good again.
- Finished the ailerons
- Ran Conduit in the wings
- Finshed the Flap Gap Fairings
- Hung the wing skins in place
- Started the Flaps section

It felt good to finish up another section of the plans and to do it so quickly when compared to the tanks. The Flap Fairings have been patiently waiting to be completed for a while and I crossed those off the to-do list. Conduit needed to be ran and I finished that as well. I cut the little tabs off the 22(?) flap ribs, sanded and deburred them as well, while grilling outside. I hung the skins in place, placed the ribs back on the shelf, then cleaned the shop and put my tools away to be prepped and ready to start the next section after Memorial Day weekend.

Friday May 17 - 1.25hrs - Riveting Ailerons
Saturday May 18 - 4.25hrs
             2.0hrs - Riveting Ailerons, proseal trailing edges
             2.25hrs - Run Conduit
Sunday May 19 - 3.25hrs
             1.75hrs - Finished Ailerons
             0.75hrs - Finished Flap Gap Fairings
             0.75hrs - Cut Flap Ribs

Finished Ailerons Total Time = 25.5hrs

I was able to use the squeezer for all but the last rivet and instead of fighting to get a solid rivet installed there (and possibly bending the edge of the aileron) I just popped a blind in and moved on. I used an MK-319 rivet instead of the the AD3 rivet that is called out. The blind rivet is weaker than the solid, but in this case the material will fail long before either rivet would, so it doesn't matter.

I used an extension on the unibit to drill through the wing walk ribs. I then sanded the holes down with a dremel to clean up the hole.

I ran all the conduit through the wings. I just enlarged the standard hole that you create in the plans. Somewhere Van's aircraft has posted that enlarging this hole to 3/4" is acceptable to run their conduit through the wings. I still went with their conduit even though the corrugated edges make it difficult to pull through the holes and I've heard it's difficult to pull wires through, for three reasons:
1. It sretches, help during flexing of the wings.
2. It's made of Nylon which has a temperature range of -40 to 185 degrees F.
3. It's cheap.

A look at the finished ailerons.

Wing bottom skins hung in place.

Wednesday, May 15, 2013

Aileron Work

After completing many small little jobs around the house, including the garden (yay!), and spending a great deal of time trying to diagnose the problem with the car.....well, long story short, I went to buy the parts on Friday and they are not in stock (every project I do I have to order something; why is that?). Parts on order allowed me to get a little work done on the ailerons.

It's been easy work these last few days, nothing frustrating. I didn't build a stand for the ailerons as I never saw a need. It was simple enough to work on my flat table top. I did screw up on cutting the extruded trailing edge to the correct lengh. It still boggles my mind how I could have messed that up since I marked the parts when they were clecoed together. But, it's still long enough to be used on the flaps so I just swapped the parts out and continued on.

Saturday May 11 - 3.75hrs - deburring, dimpling, countersinking
Sunday May 12 - 3.0hrs - riveting
Tuesday May 14 - 1.5hrs - riveting

Total Aileron Hours = 20.5

Nice and straight.
I also had a chance to fly my friend's new-to-them 1963 C182 that is in mint condition! A beautiful vintage airplane.
Finished the garden. 8'x4' bed built from cedar. Includes, but not limited to: tomatoes, squash, zucchini, onions, strawberries, peas, beans, jalapeno, peppers. My next "other" project is going to be building a small, automated irrigation system.

Monday, May 6, 2013

Sometimes things just don't work out.

Someone made the statement to me "I don't see how you do it, how do you have the time to work on the plane and have the baby"

Well it's about pattern, discipline, momentum, and an awesome wife. You create a daily pattern; start your morning, feed the baby, go to work, pick up the baby, go home, play/feed/bathe/calm/whatever with baby while wife does her thing, eat dinner, clean up, out to the shop while it's Mommy time with baby. Have discipline to stick to the pattern or else time evaporates into thin air and the night/day/week is shot. Keep the momentum going; keep repeating this until something big is accomplished. If you get tired of repeat don't worry life will interfere plenty of times to keep things interesting. Last but not least, have an awesome wife that likes the daily plan and execution as much as you do and that supports you and your decisions.

Now for that part where life will interfere.
My wife created a side project for me...."I want a garden, a raised garden bed" she said. Ok, no problem, I actually really encourage this idea and am excited to grow some fresh veggies and herbs. We've had planters and toyed around with tomatoes, peppers, and such. But now were getting a bit more serious, digging up a spot in the yard, building things, hauling know fun stuff. This should be a Saturday's worth of work, but then....

Rain all weekend, off and on, just enough to tease you. And forecast for rain next weekend just to torment you. Plans for the following weekends just to add the pressure of getting it done this weekend. Adding in Hurricane Ayla hitting ground at our household made it an intersting weekend. I mean why does a 4 month old need to cry for hours on end with no resolution possible? To add to the mix I found leaking antifreeze under the car....crap.

So let's review, I now have: an unfinished garden, a crying 4 month old, a car that needs repair, and only an hours work on the plane. .....pattern fail, discipline fail, momentum fail, but still an awesome wife.

Wednesday 1st - 1hr deburring aileron parts
Sat-Sun 4th-5th  - 1hr spread over the entire weekend deburring parts durring the rain showers.

Busy all week with other obligations and now having to fix a car....will repost when able to get back at building.