Sunday, October 19, 2014

15 OCT 14: Priming wing skins: 2 hours
Finished priming wing skins – no pics.
17 OCT 14: Page 16-2 step 6: 2 hours
Dimpled the W-1002 and W-1003 top wing skins and the W-1028A and W-1028B wing box j-stiffeners:
18 OCT 14: Page 16-2 step 6, pg 9-18 step 7, pg 9-19 steps 1-2, pg 16-3 steps 1-3: 7 hours
Finished dimpling the left wing skins – start to go crazy after a while:
Finished the right elevator trim tab.  Riveted the hinge half to the right elevator.  Gap looks pretty good:
Bent the hinge pin to be secured by safety wire:
Finished product:
Started to rivet the left wing inboard top skin – had to drill out a few rivets due to not countersinking far enough.  Went over all the holes with the countersink bit to deepen them about .001-.002.
19 OCT 14: Page 16-3 step 3: 6.25 hours
Finished drilling out several proud rivets due to not countersinking the skin far enough.  Didn't want to deform the rib flange so I drilled all the way through the rivet.  I begin with removing the head the conventional way, but then drill through the tail with the smallest drill bit I have.  I go very slow, being very careful to drill straight through.  If done carefully, this is what you end up with:
 Squeezed the end rib/nut plate rivets:
Back riveted the rest.  It is extremely slow going, but produces excellent results.  Between flipping the frame back and forth, being extremely careful positioning the back rivet plate, and ensuring the skin is flat against the plate, this method takes quite some time.  The results are definitely worth it.  Hard to get good pics, but the skin is glassy smooth:
I couldn't reach the end rivets, I’ll have to order an offset 12” back rivet set.  Got almost all of them set though:
Got the inboard skin finished.  Now that I have my system down, the outboard should go quite a bit faster:

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