Construction Log for RV-7 N395CL - Wings - 2/14/08 - 3/8/08

AILERONS -

Created Aileron brackets

Ailerons ready for priming -

Primed Brackets -

Bracket riveted on the wing ends

Another view -

Mid Spar Brackets -

Initial fitting of the Flap Braces -

Initial fitting of the Aileron gap fairing-

Aileron gap fairing primed and riveted.

Flap Brace primed and ready to rivet -

Cutting the Aileron Push Rods-

Completed Ailerons Rods (w/ thru rivets)

Another Shot -

Both Sets all riveted and complete -

Close up -

Close up on the thru rivets - not bad at all...

Drilling the Aileron Bracket Bushing -

Installing Aileron brackets

More Brackets -

Ailerons installed on the wing -

Aileron bellcrank installed -

Setting the "in trail" position on the ailerons -

WING WIRING CONDUIT -

Using a home made template to help drill the 3/4" wing wiring conduit holes.

Holes Drilled -

Using the Unibit to get 3/4" holes -

Feeding the conduit - what a pain...

1/2 Installed on the right wing -

Fully installed with silicon sealant on each hole -

Drilling Bottom Wing Skin

Deburring / dimpling wing skins

Getting ready to cut the Pitot hole:

Unibit, dremel, and file all worked to make a nice fit -

Pitot Mast fit into the wing skin -

Drilling nutplates for the pitot heater -

Heater installed with #8 screws

Pitot Mast Drilled and threaded to the Dynon Heated Pitot-

Threading the tie down mount (3/8 x 16) -

Marking the rear spar -

Excess material cut and removed -

Flaps drilled and Cleco'd -

Gap is set to 7/32" and ended up within 1/64" on the aileron to flap alignment

Hard to do much better -

Used a rubber and aluminum washer to bulkhead mount the Safeair1 Pitot fittings -

Pitot mast cleco'd in -

Riveting the flap hinge, note that I dimpled the P3 hinge without any warping or misalignment -

Rivetting the Left Wing Skin -

Yours truly cleaning up the rivet lines with some MEK -

Riveting in action - You can see I have a special hairdoo for these sessions -

Left wing skin with pitot mast fully riveted

Prepping the fuel tank inspection cover parts and fuel sender unit -

Proseal at it's finest -

One unit complete and ready to be installed -

Ready to install -

Tank cover installed with a good amount of proseal - everywhere

Trutrak roll servo installed-

Safety wired - my first attempt with the wire and it went well after the first few tries -

Aileron stops - using a 1/2" x .32 bushing per recommendations from several folks on VAF-

Bushing installed on the Aileron bolts -

Pitot installed with 3/16" AN tubing -

Riveting the right wing skin -

Another shot of the riveting in action -

The QB wings are complete (except tips) at 77 Hours!