Wings, Wing Tip (Part 12)

Tonight was a relatively short session, but we made forward progress on the Wing Tip Inserts.  In the previous session, we cut out and removed part of the Wing Tip Fairing to accept the new Insert. Now, there is some material is required to be removed from the Insert itself.  Here is the instructions excerpt from AEROLED:

 The area shown below inside the blue line (where the sticker is located) will need to be removed.  Out line was actually drawn approximately 1/4” below the blend-line.  I figured I could sand the remaining material to achieve the required fit around the AeroSun VX.

So, used my Milwaukee rotary tool and cut-off wheel to remove the material along the blue line.

Then, we used some 80 grit sandpaper to smooth the rough edges.  Again, the “hole” is slightly smaller than required.....we will enlarge the hole with sandpaper when we get there.

Here is the initial fit of the Insert into the Wing Tip Fairing.  Still some work to do, but making progress.  The Insert will eventually be epoxied into place and filled/blended with micro balloons.

Another area that will need some sanding is the trailing edge of the Wing Tip Fairing.  The plans say to even up the the trailing edge of the Wing Tip Fairing and the trailing edge of the Aileron.  We used a ruler to make the blue line on the Fairing.  Eventually, we will be sanding the Fairing to match the Aileron.  

Here is an overall view of the whole Fairing.  Not a lot of material will need to be removed.  Van’s said if any of the area separates, just fill it and sand to the desired results.

Wings, Wing Tip (Part 11)

In an earlier posting, I talked about the exterior lighting we decided to use for the RV.  During this session, we started the install of the AEROLED AeroSun VX Landing Lights.  In order to install these lights, both Wing Tip Fairings will have to be modified.  (Here is a link to the instructions from the AEROLED website).  For no particular reason, we will start work on the right Wing Tip Fairing first.  The modification calls for the removal of the forward portion of the stock Fairing and replace it with these.....

The first couple of steps (Steps 1 and 2 from the instructions) is to make reference marks at either 3.5” [88.9 mm] or 1” [25.4 mm] as shown in the plans excerpt below.

Once those reference marks were completed, we used electrical tape (or you could use fine line tape) to “connect the dots”.  Here are a couple of pictures of our Wing Tip Fairing after installing the tape.

After all the tape was applied (Step 3), a sharpie marker is used to trace the inside of the tape line.  I forgot to take a picture of our Sharpie lines, but here is an excerpt from the instructions showing what it looks like after the tape is removed. 

Next, I followed the instructions and used my Milwaukee rotary tool with a cutting wheel to cut just outside the sharpie lines.  After cutting out the area, here is a couple angles of what it looks like.  (I did use a sanding block with 80 grit sandpaper to smooth out the edges prior to taking these pictures)

The three pictures below show a couple of angles with the “new” inserted inside the Wing Tip Fairing.

If you look around the edges where the two pieces will join, you can tell the fit is not perfect.  Additional sanding will be required to get the desired fit between the two pieces.  (And ultimately some blending and filling to get the best possible result).  That is pretty much where we finished for the day.  We will pick it up from here during the next work session.

Wings, Outboard Leading Edge (Part 34)

In this session, we will install the Lens on the wing (again, we are only doing the right Wing for now).  To start, we aligned the Lens in the opening using the lines we previous drew on the tape and used the “orange tape handle” to pull it tight against the inside of the Wing.  The plans says to use plexiglass drill bits to drill holes in.....wait for it, plexiglass.  My A&P buddy (who has been helping and guiding me through out the build) said he recommended using a unibit to drill holes in plexiglass.  So, that’s what I did.  The first step on my unibit is 1/8”, so very close to a #30.  After each hole was match-drilled (very carefully), we inserted a cleco.  Here is the four holes on the top.....

.....and the four holes on the bottom.

Now, for some figuring.  The plans say to enlarge the #30 holes (1/8” in my case) we just drilled to #27 and countersink them to accept the dimples for the #6 screws on the Wing Skin.  First of all, my unibit doesn’t have a #27 step and I’m scared to countersink the plexiglass.  I don’t feel like I can countersink all the holes accurately enough not to introduce cracks (now or later).  So, I asked my buddy Jeff.  He recommended making the holes large enough to encompass the whole dimple on the Skin.  This way, all the holes will be the same, there will be no stress points on the plexiglass created by imperfect countersinks, and the Lens will sit flush on the inside of the Skin all the way around.  SOLD!

The two holes sizes came down to step #6 (9/32”) and step #7 (5/16”).....this my test piece and jig.

The #6 step was slightly too small and did not completely encompass the dimple or sit flush on the Skin.

The #7 step fit perfectly around the dimpled hole and sat completely flush on the Wing Skin.  So, #7 it is!


After bracing the Lens on the corner of the table, here are the four holes cut to the #7 step on the top.....

.....and the bottom.

After removing the tape, here is what the holes looked like....all the same sized holes and no cracks.

Lastly, we installed the Lens on the Wing using the two backing plates shown in Part 33.  Here’s the completed install showing the top.....

.....and the bottom.

Once completed, we covered the Lens with a microfiber cloth to keep dust and debris off and help prevent scratches.  Turned out pretty good I think.  We will use the same method to complete the Lens for the left Wing in a later session.

Wings, Outboard Leading Edge (Part 33)

This work session was nothing more than sanding the edges of the Lens to the desired shape.  After sanding, checking, sanding, checking, etc.....

Here is the final shape of the bottom portion of the Lens.....

.....and the top portion.  I am pretty please with the results.  In the next session, we will install the Lens on the Wing.

Wings, Outboard Leading Edge (Part 32)

Seems like so long ago since we completed Parts 30 and 31.....May 17-18, 2018.  Fast forward about 2 1/2 years and we’re back.....for the landing light Lenses.  The first step was to place the Lens on the Leading Edge and mark a line approximately 3/4” [19.0 mm].  I used a ruler and made many little marks at 3/4” and then free handed the marks to make the line you see in the pictures below.   This step is mostly necessary to remove a large portion of the edges so the Lens will fit into the opening in the Leading Edge.  This is the top.....

.....and the bottom.

The areas “outside the lines” marked above was then removed.  However, prior to completing this step, I covered the Lens with tape to protect it from damage.  I then used a belt sander to remove the material.....slightly short of the lines marked above.  Here is one side.....

.....and the other.

Once the appropriate amount of material was removed, it fit easily into the landing light opening on the leading edge of the Wing.  The plans instruct you to use tape to make a “handle” to pull the Len snug against the inside of the Wing.  If your working by yourself, this actually worked pretty well.  If you have a helper, they can easily reach into the end of the wing and press it forward.  Once pulled or pressed agains the inside of the Wing, the opening in the leading edge was traced onto the Lens.  (Another good reason to tape the Lens so you don’t draw directly on the Lens).

Next, the W-0018 Backing Plates (prepared in Part 16) were clamped to the Lens as shown below.  Then, a line was traced on the Lens along the upper end  (or aft end) of the Plates.

Lastly, a final line was marked at 1/4” [6.3 mm] above the line created with the Backing Plates.  This is the smaller blue line at the top.  Here is the top (which actually looks a little skinny on the top left and right edges....I’ll confirm prior to sanding).....

.....and the bottom.

I’ll pick it up here during the next work session.

Finishing, AEROLED’s Sun Spot LX (Part 2)

After preparing parts during the previous session, today I treated them with Alumiprep, Alodine and Akzo Primer.  After they dried, I installed the eight K1000-06 nutplates on the two W-00016B AEROLED’s Sun Spot LX Brackets using AN470AD3-3 rivets (easily hand squeezed). 

Lastly, I sprayed them with flat black paint.  They are now ready to be installed with the landing light (during a later session).

Empennage, Fairings (Part 7)

In Part 4, I completed the work on the Tail Light Adaptor Ring on the bottom of the Rudder Fairing.  The last thing I needed to do was enlarge the center hole enough for the rear of the AEROLED Suntail to pass through the Fairing.  I used step bit and enlarged the hole one step at a time.  Ultimately, 1/2” was the size that worked.  Here is what it looks like.

In this picture, you can see the aft side of the Suntail showing what needs to clear the Fairing.

The screws aren’t installed in the Suntail, but here is what it will look like in the Fairing.

Finishing, AEROLED’s Sun Spot LX (Part 1)

As we mentioned before, we decided to go with AEROLED’s for exterior lighting.  There are a few parts and pieces that came with the option that need to be prepared for the actual light install (in a later session).  Since we are installing a landing light in each of the leading edges of the Wings, we were sent two install kits.  In the plans excerpt above, the W-00017 Mount Bracket is already installed in the Wing.  Shown here is the two kits from Van’s.

I prepared the W-00016A Retainer Rings (x2) and W-00016B AeroLED Sun Spot LX Brackets (x2).....all the edges were cleaned and the holes deburred.  Additionally, eight (four for each light) W-00021 Spacers were fabricated using .058x5/16 6061-T6 tubing.  Each Spacers is 0.395” [10 mm] and is shown in a pile below.

All the parts are now ready to be treated with alumiprep, alodine and Akzo primer.  Since they will be installed inside the black portion of the Wing, these parts will also get painted black.

Wings, Wing Tip (Part 10)

Alright, the Ribs have dried overnight and are ready to be installed in the Wing Tip Fairings.  I clecoed the Ribs into place on their respective Fairings and installed the rivets.  The aft three rivets on the top and bottom of each Fairing are MK-319’s and the rest are AN426AD3-3.5 rivets.   I used my gun and bucking bar to set the solid rivets and hand rivet puller for the MK-319’s.

The plans advise “When setting solid rivets in fiberglass composites, use soft rivets or leave normal rivets with a longer shop head (approximately 1.2 x the hole diameter)”.  I used solid rivets and followed Van’s guidance.

Here is the top of the right Fairing with all the rivets set.....

.....the bottom of the right Fairing.....

.....and the inside of the right Fairing showing all the shopheads.

Here is the top of the left Fairing with all the rivets set.....

.....the bottom of the left Fairing.....

.....and the inside of the left Fairing showing all the shopheads.