Fitting Left leading edge w-408 rib - 4 hours

It was finally time to finish preping the W-408 leading edge ribs. I slid one rib into the leading edge assembly and marked the holes with pen to give me an idea of where to flute the ribs.

I then transferred those marks over to the other rib. It was not time to double check the flanges were 90 degrees. I broke out the rib straightener and made some adjustments.

I then fluted the ribs. The left one went well, but the right just gave me brain damage. Not the easiest to work out. I was satisfied that it was sorted out, but not a perfect as it could have been. In any case, I fit the left rib into the leading edge assembly and clamped the rib to allow match drilling the aft flange with the spar. It came out pretty nice,



I then clecoed it back into place.

Next it took me some time to figure out where/how the w-423 joint plates come from. I finally noticed the note on drawing #12 section F-F. going into my inventory I found the 2 AS3 strips. I slowley worked it out that these do not need to be cut down. The are the correct length to begin with.
I then came up with the idea to fit then around the rib to double check the correct fit and also to pre-bend the strip. This turns out to be a fairly important step. I made sure to even out the slight overlap on each end and mark it.

 Then....I followed the plans to fit the joint plate in. The process for me was quire slow and lots and lots of adjustments back and forth to get just the right fit. I then started to match drill and cleco. Checking and re-checking as i went.


A long process...But extremely nice on how it turned out.

Stall Warning Hatch - 2.5 hours

I started in on sorting out the Stall Warning hatch. I little bit of thought goes into as the kit is designed to be an add on to an existing plane, but there a few steps that you can skip as they are not applicable. The supplied template is just scrap because the left leading edge is prepunched with the correct hole locations.



Not much to report for the hatch. The holes did not need match drilling (I made sure for each hole anyway) so I buffed the holes, deburred slightly, and dimples for the screws. I then went to work on countersinking the holes for the rivets that hold the platenuts. These are done by hand with the deburring tool and take some time to fool around with and get right. I DO NOT want to countersink too far. I opted to use the NAS Opps rivets for these rather than dimple them.


I did a trial fit of the hatch cover over the area, and I must say that there is quite a gap all around. Not sure that I am too keen on the fit. Maybe I need to make a new custom hatch??

Finished drilling left wing skin and fitted leading edge - 5 hours

I really wanted to finish the match drilling of the wings skins today. I put my head down and got it done. Since I only have 325 clecos I had to take the skins off the right wing and use all of those clecos for the left wing. I spent a lot of time taking messing with the wings, taking them off the stand, putting them back on the stand, checking level, checking twist, adjusting, clamping. The good news is that I am becoming a master at it.
I managed to finish the match drilling of the left wing skins in a matter of a couple of hours.


 
I created a template to help mark out the tie down bar. Then, I removed the clecos for the bottom skins. I really took a good look at the structure. Lots of metal shavings inside...I know straight away that I should remove the top skins as well. The metal shavings like to get into the matting surface between the skins and the rear spar. I think it best to get all the shavings out, so I uncleco'd the skins, wiped the left wings skins and wing skeleton. Then I cleco'd the top skins back on the wing. A very long and tedious process....but it's the right thing to do.
Did I mention the pneumatic cleco gun is amazing?
I was finally ready to put the left leading edge onto the assembly. It slipped on very nicely and just needed a tad bit of pressure to get the holes to line up for cleco's. Once the clecos where in....I stood back and admired the fit. Well done Vans, Well Done.

Starting to match drill the left wing - 3 hours

I am very motivated to keep on trucking on the wings. I decided that the only way to get some real progress done this weekend is to remove all the clecos from the right wing and left leading edge, and use them to match drill the left wing skins. A bit of a waste of time to remove all the clecos only to have to reinstall them later. But time I have....clecos I do not.
Besides....This plays well with the fact that my wing stand has little access in between the wings.
I removed the right wing from the stand and placed on the table. I set the left wing up and on the stand and began the process of checking level, twist, etc. Not a quick process but I managed to start clecoing the skin on.
 
I also took this opportunity to take a better look at the rear spar rivets that the drill made contact with when match drilling the rear spar. It looks so much better than I originally thought. I took out the dremel and placed electrical tape around the area. With a small buffing wheel on the lowest speed, I very carefully touched up the factory heads to remove and sharp edges. only took a second, but I am extremely pleased how it turned out.

Started the stall warning assembly - 1 hour

Another stellar night of little progress. I decided to jump into the stall warning assembly. I cut the mounting brackets and made sure I was working on the correct piece. I trimmed, deburred and cleaned up the edges on the mounting bracket.
 
Step 2 - Match drill #10....Ahh Crap. I do not have a #10 drill. Reading a bit further...Match Drill #31. Yup...Don't have that either. 


Isn't that the way it goes. I just put in a huge order yesterday...and totally missed these.
So I decided to never have this particular issue again cause it keeps rearing its head....I ordered the 1-60 drill set from Cleveland.  

Local builder meetup & Clecoed the left leading edge assembly - 1 hour

Another small night on the build. I clecoed the left leading edge assembly.
 




I met a few new local builders tonight. It's always great to get to know those in the game, and always a pleasure to learn from those more experienced than I. The group spent some time talking 'shop' and I was able to show some of my progress off. I was pleased to get some positive feedback and also some pointers.