Wings Continued - Right Wing

Right Wing Assembly



Skeleton Riveted Together

7/21/12 - Assembled Right Wing Skeleton with clecoes and riveted it together. Cut "L" Angles to size that will fit inbetween the rear ribs, drew a centerline and drilled a starting hole that was 10 mm from the end. Drilled holes in the Bottom Skin (75W6-1) and through the "L" angles. Clecoed "L" angles in place and fitted bottom skin to the wing skeleton. Total Time = 6 hours.


Drilling Holes to Proper Size

 7/22/12 - Clecoed bottom skin in place and drilled out all holes to the proper size. Installed Inboard Trailing Edge Skin (75W6-3), Outboard Trailing Edge Skin (75W6-4), Inboard Nose Skin (75W5-1), Outboard Nose Skin (75W5-2) and clecoed in place. Dilled out all holes to proper size in the spars and ribs. Clecoed Flaperon Brackets in place and drilled holes in the Flaperon "L" brackets. Total Time = 5 hours.

All Skins in Place

Installed Strut Brackets



7/28/12 - Installed strut brackets and drilled holes into the bottom skins as well as into the brackets. Set aside brackets to be riveted at a later time. Total Time = 3 hours.


Adding Cortec Anti-corrosion Material



7/29/12 - Removed all skins from the wing skeleton and deburred the wing skeleton. Deburred all skins and "L' angles. Cleaned all parts and added Cortec anti-corrosion protection. Reassembled skins to the skeleton with clecoes. installed rivets into the holes and riveted all skins to the bottom of the wing. Total Time = 12 hours.



Riveting the Skins



Bottom Skin Riveted in Place

 8/4/12 - Drilled holes in the "L" angles and clecoed them to the underside of the top skin (75W5-4). Clecoed the Flaperon Brackets to the wing skeleton.


Top Skins Clecoed to Skeleton

8/4/12 - Installed the top skin and the tank cover skin (75W5-3) to the wing skeleton and clecoed in place. Measured 70 mm from the trailing edge to the flaperon arm. Drilled holes in the trailing edge skin and clecoed in place. Drilled out all of the holes in the top skins to the proper size. Total time = 4 hours.



Leading Edge Top Skin Ready to be Pulled Over Ribs

8/11/12 - Pulled the Leading Edge over the main wing spar with straps and drilled holes in the skin to the proper size. Removed the top skin, tank cover skin and deburred the wing skeleton. Total Time = 7 hours.


Deburring Skeleton

Deburring Sharp Edges on the Tank Cover Skin

8/12/12 - Deburred the Top Skin and the Tank Cover Skin and added corrosion protection. Riveted the Flaperon Brackets in place and finished adding corrosion protection to the wing skeleton. Riveted the Tie-Down Bracket and the Rear Attach Bracket to the Wing Skeleton. Total Time = 5 hours.


Riveting Flaperon Brackets

All Brackets Riveted

9/2/12 - Cut cork to the proper size and applied to the fuel tank. Fitted fuel tank into wing and made adjustments as necessary to get a proper fit. Total time = 5 hours.

Fuel Tank Fitted Into Place

9/3/12 - Cut a hole in the fuel tank with a flycutter for the sender unit to fit into. Installed the fuel channel (75K1-2) into the wing skeleton. Installed the tank cover and drilled holes into the fuel channel and cover and clecoed in place. Cut "L" angles and installed them into the wing tip area. Total time = 6 hours.


Cutting Hole in Fuel Tank with Flycutter

Installed the Nose Rib (75W4-1) and riveted in place. Installed the Root Rib Doubler (75W4-3) and riveted in place. Flattened one end of the Root Rib Angle ( 75W6-5) and then crimped to follow the curvature of the Root Rib. Installed the Root Rib Top Skin (75W5-5), drilled holes and clecoed in place. Total Time = 7 hours.


Root Nose Rib and Doubler Riveted in Place

9/9/12 - Installed the Wing Tip (75W6-8), drilled holes and clecoed in place. Total Time = 3 hours.



Drilling the Wing Tip and Clecoing in Place 

9/16/12 - Installed the sender unit (226-451D) inside the fuel tank. Installed the Nav/Strobe light in the end of the wing tip. Also enlarged the hole in the bottom of the wing for a better fit for the fuel drain. Total Time = 5 hours.


The Nav/Strobe Light Installed

 9/21/12 - Attended Zenith's 20th Anniversity Open Hanger Event in Mexico, Mo. Gathered lots of valuable information about painting the aircraft after completion and different engine choices for the CH750. Also attended the Friday night banquet in which Rod Hightower spoke on behalf of the EAA.



Open Hangar Day

9/22/12 - Had a chance to talk to fellow Zenith builders which was invaluable. Learned more about the Jabiru, UL Power and Viking engines. Was quite impressed with the Viking fuel-injected engine so much so that I decided to take a Demo flight with the owner of Viking, Jan Eggenfellner. After that flight, I was sold. It was very powerful and did not have the vibration that I expected or excessive noise either. I had finally decided on the powerplant for my build!

Viking Powered CH750 Demo Plane

9/28/12 - Found out that I could upgrade to Edition 3 CH750 while I was at Zenith last weekend. This upgrade includes a smoked glass aerodynamic top window. Recived the upgrade kit from Zenith today and I can't wait to start installation on Saturday.

9/29/12 - Removed the old Root Rear Rib (75W4-2) by drilling out the bottom rivets and Root Rib Doubler and installed the upgraded Root Rear Rib (75W4-2/1). Total Time = 2 hours.



Look at the Difference Between Root Ribs

  10/6/12 - Since I have decided on using the Viking engine with a header tank, I installed a pipe plug in the return line port of the fuel tank. Also placed cork on top of the fuel tank so that it doesn't rub on the fuel tank top skin. Installed the new Wing Root Top Skin (75W5-5/1). Total Time = 2 hours.


New Root Rib Installed

10/7/12 - Dilled out rivets on the bottom of the wing to accomodate the new Wing Root Nose Skin (75W5-6). Installed new nose skin and pulled tight to drill new holes into the new Wing Root Rib. Drilled all holes to their proper size, deburred, cleaned and applied anti-corrosion protection. Opened up hole in the fuel tank top skin with a file so that it doesn't touch the gas cap. Installed cable clamps  into the rear spar for the wiring of the Nav/Strobe & Landing Lights. Total Time = 8 hours.

Cable Clamps in Place

Nav/Stobe Light Wired In

10/20/12 - Opened up hole in the rear spar so the fuel supply grommet could be installed. The fuel hose was then routed through the grommet and exited out the back of the rear spar. Attached the fuel hose to the supply nipple with the supplied radiator style hose clamp. Drilled out machining hole in the rear spar and installed the grommet for the sender unit wire. Wired up the Nav/Strobe light and and verified the continuity of the wires at the root end of the wing. Bolted the strut support bracket into place and riveted the bracket assembly to the bottom of the wing. Total Time = 11 hours.


Fuel Hose Routed from Tank Through Rear Spar

Strut Support Bracket Assembly Riveted to Bottom of Wing

10/21/12 - Replaced a cracked fiber washer on the fuel tank sender unit attaching screw. Wired up the fuel sender unit and attached the ground wire to the fuel tank grounding lug on the sender unit and the tank. Riveted the ground wires to the root rib. Added more cork to the fuel tank and installed the tank in the wing skeleton. Riveted the fuel channel in place and then pulled the nose skin over with straps and clecoed nose skins in place. Began riveting the nose skin at the top middle part of the leading edge. Total Time = 8 hours.



Fuel Tank Wiring in Place.

10/27/12 - Verified the Landing Light wiring. Drilled a hole in the Nose Skin and installed a grommet for the Landing Light wiring to pass through. Finished riveting the rest of the Right Wing. Removed the Left Wing from the brackets on the wall and placed it onto the sawhorses. Hoisted the Right Wing onto the brackets on the wall. Total Time = 7 Hours.

Landing Light Grommet in Place



Completing the Riveting



Finished Right Wing

Right Wing Hung on the Wall

Right Wing Total Assembly Time  = 122 Hours.

Wings Continued - Left Wing

Left Wing Assembly - Moved to the Garage!

Changed to saw horses.

Riveting Skeleton with Pneumatic Riveter

4/8/12 - Assembled Left Wing Skeleton together in the garage with clecoes and prepared to rivet. Riveted entire skeleton together using a pneumatic riveter. Total Time = 4 hours.



Finished Left Wing Skeleton

4/14/12 - Cut "L" Angles to fit in between the rear ribs and drilled then clecoed them to the bottom skin. Attached Inboard Bottom Skin (75W6-1) to the Wing Skeleton. Total Time = 4 hours.



Adding "L" Angles

 4/15/12 - Placed Outboard Bottom Skin (75W6-2) on the Wing Skeleton and clecoed in place. Drilled out bottom skin holes to proper size. Installed Inboard Nose Skin (75W5-1) and Outboard Nose Skin (75W5-2) and clecoed in place. Drilled out the rib and spar line holes to the proper size. Installed the Inboard Trailing Edge Skin (75W6-3) and the Outboard Trailing Edge Skin (75W6-4) and clecoed in place. Drilled out the holes in the edge of the trailing edge spar to the proper size. Placed Flaperon Brackets in place, clecoed them to the Wing Skeleton and drilled holes in the Flaperon "L" Brackets. Total Time = 6 hours.

Drilling out holes to proper size

 4/21/12 - Deburred the training edge skins and set them aside. Deburred the top part of the bottom skins. Total Time = 2 hours.

Deburring Bottom of Wing Skeleton

4/28/12 - Deburred the bottom part of the bottom skins and the "L" Angles that fit between the rear ribs. Deburred the Trailing Edge Spar, the Leading Edge Spar and the bottom part of the Ribs. Total Time = 4 hours.



Applying Anti-Corrosion Material


4/29/12 - Removed all labels and cleaned surfaces with laquer thinner. Coated all surfaces with Cortec anticorrosion material. Reasembled the wing assembly with the bottom skins, the nose skins and the training edge skins. Drilled holes in the bottom skins and the strut brackets for installation of the strut brackets to the bottom of the wing. Strut brackets to be riveted at a later time. Total Time = 7 hours.



Bottom Skins Loaded with Rivets

5/5/12 - Removed the strut brackets and deburred, cleaned the surfaces and coated with cortec anti-corrosion material. Installed rivets in drilled holes and riveted all bottom skins to the bottom of the wing. Installed the flaperon brackets with clecoes. Total time = 8 hours.



Riveting the Bottom Skin



Bottom Skin Riveted



Clecoing Flaperon Brackets in Place

5/6/12 - Installed "L" Angles to the top wing skins and clecoed in place. Also clecoed outboard top skin (75W5-4) in place and then drilled holes in top skin to proper size. Total time = 2 hours.



Adding the Outboard Top Skin

5/12/12 - Placed the Tank Cover (75W5-3) on skeleton and clecoed. Drilled out holes to proper size. Measured trailing edge to 70 mm to the Flaperon Arm and then drilled into trailing edge and clecoed trailing edge in place. Total Time = 5 Hours.


Tank Cover in Place

5/12/12 - Drilled leading edge of top skin, clecoed and then removed them. Pulled Leading edge into place with straps and clecoed skin in place. Drilled out remaining holes to proper size. Total Time = 4 Hours.



Dilling into Leading Edge



Final Holes Drilled and Clecoed



Ready to Loosen Straps

5/19/12 - Removed all skins, deburred holes in skeleton and top skin. Also riveted Flaperon Brackets in place. Total Time = 3 hours.



Riveting Flaperon Brackets.

5/19/12 - Cleaned all surfaces and applied anti-corrosion material. Also riveted Rear Attach Bracket. Total Time = 3 hours.



Riveting Rear Attach Bracket



 5/20/12 - Installed Pitot Tube (75W6-9) to the bottom skin of the wing after drilling a large hole that I could fit the Pitot Tube through. Clecoed Pitot Tube in place after drilling holes. Total Time = 2 hours.




Pitot Tube Clecoed in Place


5/26/12 - Cut the plastic tube and attached the Pitot Tube and then tie wrapped the Pitot and Static plastic tubes together. Drilled holes in the rear spar and routed tubes to the root end of the wing. Total Time = 2 hours.



Pitot Tube Routing

5/27/12 - Fitted the Left Wing Tank (75K1-1) into the left wing and clecoed the Fuel Channel (75K1-2) to the bottom skin. Total Time = 2 hours.



Fuel Tank Fitted into Place

 
5/27/12 - Cut a hole in the side of the fuel tank with a fly cutter for the Fuel Sender Unit (226-451D) to fit into. Total Time = 4 hours.



Hole Cut for Sender Unit

5/27/12 - Cut cork to proper size and applied to the Fuel Tank so the tank wouldn't touch the wing skeleton or wing skin at any point. Total Time = 3 hours.

Cork Added to Fuel Tank

5/28/12 - Cut 2 pieces of "L" angle 113 mm long, trimmed the corners, drilled holes in the "L" angles and riveted them to the Fuel Channel. Drilled holes into the ribs and clecoed the Fuel Channel into place inside the wing. Total Time = 4 hours.



Fuel Tank & Channel in Place

6/2/12 - Cut an "L" angle to 255 mm, layed out a center line on the "L" angle, drilled holes on the center line and riveted it to wing tip. Cut a 50 mm "L" angle, drilled holes and riveted it to the rear channel on the wing tip. Total Time = 1 hour.




Adding the "L" Angles to the Wing Tip

6/2/12 - Bent Sender Unit Arm to the proper angle and installed sender unit into the fuel tank with gaskets and associated hardware. Total Time = 3 hours.

Sender Unit Wire Bent to Proper Angle



6/2/12 - Pulled Wing Nose Skins back in place with straps. Fitted Wing Tip (75W6-8), drilled holes and clecoed in place. Total Time = 3 hours.



Wing Tip Added

6/2/12 - Flattened end of Wing Root Angle (75W6-5) and used a fluting pliers to put crimps on the Wing Root Angle to match the curvature of the Root Rib. Clecoed Nose Rib (75W4-1) in place and then riveted to the wing skeleton. Drilled, clecoed and riveted the Root Rib Doubler (75W4-3). Total Time = 4 hours.



Nose Rib & Doubler Riveted in Place


6/3/12 - Installed Rib Root Top Skin (75W5-5) and clecoed in place. Wrapped the remaining skin around the Root Rib and drilled holes to proper size and clecoed in place. Total Time = 4 hours.



Root Rib Top Skin in Place

6/9/12 - Drilled holes in the Wing Tip for the installation of the Aero LED Nav/Strobe Light. Glued gasket in place on the base of the light and attached the bracket to the wing tip using associated hardware. Total Time = 3 hours.



Nav/Strobe Light Bracket Attached to the Wing Tip

6/17/12 - Ran 2 pair 22 gauge shielded wire from the root end of the wing to the wing tip for the Nav/Strobe light. Also ran 2 pair 22 gauge shielded wire from the root end of the wing to the wing tip for the Landing Lights that are mounted on the Leading Edge Slat which will be installed later. Total Time = 1 hour.

2 Pair Shielded Wire Run for Nav/Strobe & Landing Lights


7/15/12 - Clecoed nose skin and top skin in place, transfered left wing assembly to storage position on wall of garage. I will complete assembly later. Cleaned up garage and postioned saw horses to begin assembly of right wing. Total Time = 4 hours.



Hung Left Wing on Garage Wall

10/28/12 - Left Wing is off the wall and back on the sawhorses.Unriveted the old Root Rib and installed the new Root Rib with clecos. Installed the new Root Nose Skin . Total Time = 4 Hours.



New Root Rib with New Nose Skin

11/3/12 - Fitted Root Nose Skin and drilled holes to proper size, then disassembled. Total Time = 2 hours.

Plug Installed in Gas Tank

11/11/12 - Deburred, cleaned all parts and applied anti-corrosion Cortec. Installed the plug in the gas tank return opening. Installed the new root rib and riveted it in place. Added cork strips to the top of the gas tank. Total Time = 5 hours.

Cork added to Top of Tank

11/17/12 - Drilled out holes in the rear spar for the fuel supply hose grommet. and the sender unit wire grommet. Installed Nav/Strobe light in the wing tip and connected wires. Ran wires for Nav/Strobe and Landing Lights and installed cable clamps down the rear spar area to the inboard side of the wing. Installed wiring for the fuel tank and prepared for final assembly of the wing. Total Time = 9 hours.


Grommet Holes Drilled

11/18/12 - Measured the Strut Fitting Bracket and trimmed it down to fit the curvature of the Strut Bracket. Installed the Strut Fitting Bracket and and riveted in place. Riveted the Jury Strut angles in place on the bottom of the wing. Completed riveting the rest of the Left Wing. Total Time = 9 hours.



Strut Bracket Bolted Down



Completing the Riveting



Completed Left Wing

 Left Wing Total Assembly Time = 135 Hours.


Both Wings Completed and Hanging on Garage Wall