Fuel tanks are finished

Sorry for the lack of updates but we spent a few days sealing the last fuel tank.  There really aren't any good pictures as proseal is sticky and we didn't wnat to get it on the camera.  The good news is that the tanks are sealed and curing awaiting a pressure test.  I won't be sad to see the end of the proseal.

The completed second tank.

Multiple updates - vert stab, elevators, rudder and fuel tanks

Sorry for the lack of updates.  We've actually been working but I just haven't taken the time to update the site recently.

 After the inspection we worked on wrapping up any of the things that the inspector noted.  First up was re-doing the rolled leading edge on the rudder.  It was a fairly simple job.  What it did point out was the increased level of confidence in our abilities.

After that we moved onto working on the ailerons.  We did most of the work but we simply aren't happy with the results.  The skins is a little too wavy and that can induce drag and lower our speed.  We've decided to redo them now that we have more experience with metal.  It will equate to about 7 hours of work but it'll be worth it.

We then closed up the vertical stabilizer.  It's now completely finished and ready for installation on the fuselage (once that it ready).  

After that we got to work finishing up the trim tab (it's a part on one of the elevators that is kind of like cruise control in a car) and then the right and left elevators.

Finally we continued working on the fuel tanks and have sealed one of the tanks.  We need to let the sealant cure before we pressure test it.

What's left?  We have to rivet the trailing edges on the rudder and both flaps and seal the last fuel tank.

February 16th

The rudder's inspection sticker.

Scott squeezing a few rivets.

Darren Squeezing a few rivets.

A finished piece!

February 19th

Darren squeezing some rivets on the trim tab.

February 21st

Scott working on our ultimately unsuccessful attempt to fix up the ailerons to our satisfaction.

February 26th

The elevator prior to attaching the trim tab.

Scott working on attaching the trim tab.

Darring sqeezing some rivets.

Scott showing off the installed trim tab.

A finished piece! 

March 5th

A shot of the tack prior to riveting.

After riveting.

Inside.

 From the side.

Finished elevator (non trim tab side).

Fuel tank completion and Trim tab

Today we finished up the fuel tanks.  We first finished up the wiring for the fuel sensors (we needed some additional connectors) and did the final work on installing the fuel pick up tubes.  Once that was done we worked on the assembly of the trim tab.  The first problem was to bend over the end flaps.  We've certainly developed a lot of confidence with metal working and the trim tab looks pretty good (if we do say so ourselves).  We did some basic assembly and have set the trim tab aside for the inspector.  Speaking of the inspector, the paperwork has been submitted and we're waiting for a call to setup the appointment.  We been told that it takes weeks so we're not getting too excited (yet).  We'll move back to the fuselage in the interim.

 

January 22nd

 

Interior tank shot following installation of the fuel pickup tube.

 

 

Exterior tank shot following installation of the fuel pickup tube. 

 

On to the trim tab.

 

Our trim tab bending tool.

 

Darren working the drill.

 

Our new drill we picked up at Air Venture in Oshkosh, but have not included in a picture yet.

 

 

 

Darren cleaning up the trim tab prior to priming it.

 

January 29th

 

Bending in the sides of the trim tab.

 

Scott bending in one side of the trim tab.

 

The finished product.

 

Darren trying to look busy.

 

The trim tab after assembly is complete.

 

A close up of the trim tab.

 

The trim tab from another angle.

 

The fuel sensor plate we were able to complete after receiving the missing sensor.

Fuel tank vent line and sensors

We spent time this weekend working on the "plumbing" for the fuel tank.  As you can imagine the fuel tank needs a vent line installed so that as fuel in removed from the tank it doesn't collapse (think of sucking juice of a juice box, without air coming in the box collapses).  We used our flaring tool and straightened out a coil of the vent line.  We also started work on the wiring for the fuel sensors and installed the sensing plates.  We ran out of a few electrical components that we'll order and have for the next building session.

 

Scott using the flaring tool on the vent line.

 

Interior shot of the tank where the vent line attaches.

 

 Exterior shot of the tank where the vent line attaches.

 

The fuel sensor plate.

 

A shot of the vent line after some wiring has been completed.

Shop is finally finished - worked on fuel tanks

Well, after many weekends of effort insulating the attic (it was just too cold to work), installing lights and organizing, the shop we're back at it.  Today we installed another space heater and the last two lights.  After that we spent around 3 hours working on some of the last details of the two fuel tanks.  We started on the fuel tank vent lines by installing the fittings in the end of the tank.  It was also time to start on the wiring for the fuel sensors.  Those fittings were installed on the tank as well.  Of course, we needed to mix up some more proseal to ensure that the tank doesn't leak.  I'll admit that the tank leaking is my biggest worry. 

 

 

 

A photo of one of the tanks with the fuel vent line (the blue one) fitting installed.  You can also see the capacitive fuel sensor connector.  I drew a red box around the parts because I felt like getting fancy. :-)

 

 

This is the inside of the fuel tank.  You can see the fuel vent line fitting and the sensor wire.  All the grey stuff is the fuel tank sealant.  

 

I tried to take a picture of the fuel tank vent lines (we used our flaring tool for the first time) but for some reason my camera couldn't focus properly. 

 

We would've installed the end plates and fuel pick up tubes today but we are missing a couple of nuts (no comments from the peanut gallery).  Those are on order from Aircraft Spruce in Toronto so hopefully they'll arrive shortly.

Finally back in the shop

Well, let's just say that the move didn't go so well.  Less than a week after moving into my new house, Darren and I were starting to insulate and hang drywall in the workshop.  After a crash, xrays and a doctor setting the break, I spent the next 6 weeks in a cast for a broken wrist and the month after that getting mobility and strength back.  But, the shop is now finished and we got back at the plane this past weekend.  We've decided to do the last few things on the empennage and wings so that we can have the inspector come.  So, you won't see any major new parts for a little while because once the inspection is finished we're going to close up all the horizonal stabilizer, vertical stabilizer, elevators, rudder, fuel tanks, ailerons, and flaps.  All the parts are ready for the final work and it will be nice to have parts completed. 

Scott working on one of the fuel tanks.

The fuel tank.

Scott gearing up for some priming, or possibly mixing up some tank sealant.

The bracket primed and riveted in place.

Another of the bracket.

Our new bucking bar

Lefty and Righty are ready for inspection

Darren and I took a day off work to wrap up work on the ailerons -- lefty and righty.  Because they're relatively straight-forward we built both ailerons together.  We started off by wrapping up dimpling the main skins.  Next we began assembly by attaching stiffner plates and plate nuts to the main spars.  After that we riveted the nose ribs to the counter-balance (a relatively heavy piece of stainless steel tube).  The final bit of skeleton assembly was to rivet the nose rib assemblies and the main ribs to the spar.  

After that we clecoed on the main and leading edge skins and began the process of riveting.  The remaining rivets will be set after the inspection.

Darren clecoing the nose ribs to the counter-balance tubes.

A picture of the aileron plans

Darren happily blind-riveting the nose rib to the counter balance

Lefty in the "Saddle" for riveting

Lefty and Righty on the bench after riveting (note that the shop was also vacuumed)