Wings, part 1 (click on image to enlarge)
Center spar section made in two days with help from Steve Rahm during an assist visit. It turned out beautifully.
|Pultruded carbon rods for the caps.||
Here's how the ends were finished off.
Center section with phenolic embedded and sandwiched between lay-ups.
|Right main spar inner bid and caps in. It still needs to be filled and phenolic attachments added and out BID.||Left spar completed, both filled and wrapped.|
|Ribs being bonded to main spar.||Rear spar fitted.|
|Used backless SFT's, no duct tape, instead used peel-ply on the side under the foam. The aluminum tape was used to keep the glass from sagging on the underside.||Resulting flanges||Here's a new method of putting on one side of the skins I picked up from Steve Rahm. Using a straight edge to hold up the skins, then tacking then in place with CA.|
|The clamped straight stock gets an 1/8" spacer (two popsicle sticks) to drop the panel past the ribs - for sanding flush later.||Cut the holes for the aileron push tube.||Cut phenolic plates and fitted and prepared for landing gear attachment.|
|Left stub wing, flanges for closing.||Radiator in place with plumbing.||Aileron push tube routing.|
|Access hole for radiator plumbing.||Push tube through landing gear support..||Aileron idler at end of stub wing. Will get a support block soon.|
|Outer rib of stub wing.||Wing root.||Idler support.|
|Stub wing about done, about ready for top skins and access panels. I used 1/2" plastic tubing as a housing to run the brake lines in case they ever need to be replaced.||Here's where the 1/2" tubing exits near the gear leg.||Spar leveled, triple check and drilled.|
|Rib on spar.||Ribs marked with popsicle marking jig.||To keep tension on the lacing cord, I had help from my 2x4 friend.|
|Leading edge ribs shaped.||Left wing ribs shaped.||Here's an alternate way to attach the bottom skins without making the flanges first. Saves a little time and weight|
|Using a long straight edge with 1/8" thick spacers, hold he skins in place, the tack with CA glue.||Move the straight edge along and keep tacking on the top side.||Leave them hang so they can be trimmed, then individually hold them up and tack with CA for the remaining 5 inches.|
|Skins trimmed, scuffed and prepped for BID||BID placed in each box.||Underside before sanding.|
|Attached aft ribs||Then skins with CA using a long straight edge as a guide.||Not bad.|
|View of root wing box.||Skins trimmed and rear spar tacked in place.||Leading edge foamed.|
|Flipped wing. Approximate weight was 30-40lbs at this point.||Mark guide ribs at 10 percent increments.||Used a long sanding board and followed matching increment on root and outboard rib.|
|More sanding, rounded over all sharp edges.||Rear spar attachment.||
Spar dug out, prepped for glassing.
This was a low spot on a panel. I encircle it with aluminum tape, then used two-part urethane foam with some 4 mil plastic to pat it down. It worked well.
|Left wing sand, ribs cores dug out, and spar cleaned up to be glassed.||Leading edge joggle.|
|Left wing glassed. Drilled small holes on level line where pins (finish nails) were used to support a straight edge. Then a SmartTool level was used to level both ends during the cure.||Left wing re-installed.||Right wing leading edge foamed and sanded.|
|Right wing sanded, rib cores dug out and spar cleaned up.||Right wing micro'd and glassed.||Shows where glass intersections cross at spar.|
|Leading edges trimmed.||Ribs marked and scuffed for flanges.|
|Use a Laser level to mark the aileron tube placement.||Holes cut.||Actually checked with a string.|