Month: November 2014
The first two ribs need modified so the root carry though gussets and brackets can be installed.
The #1 rib at the rear spar looks like this.
At the front spar.
The root rib was a little more difficult to cut out since it is laminated with plywood.
The slots for the brackets looks good.
When assembled everything for together well.
Now that all the main ribs are completed I can start assembly of the right wing.
The wing spars were rather simple to complete. Once the frames were completed I glued the plywood sheeting on them.
My crew of cheap labor had a great time removing staples.
I then feed the spars through the table saw to cut the angle in the top of each spar.
Lastly glued the RS-561 center gussets in place.
The root gussets are not glued on at this time, they are added during wing assembly.
Former 3A is mounted at an angle requiring a beveled RS-9. Since I am installing a BRS parachute I have a slight problem that also needed solved.
The left bridle for the BRS needs to be routed behind F-3A and follow the former to the other side. Trying to find an elegant way to do this while still being able to open the canopy seemed elusive. What I decided to do is move F-3A forward a couple of inches so it’s directly in front of the bridle.
I made the RS-9 blocks that support the former and started working to mount them. I first clamped a straight edge to the fuselage where I wanted the back of F-3A located, just forward of the bridle exit points.
Then I glued the RS-9 blocks in place and clamped them. I was careful to set the block in from the edge of the fuselage to leave room for the plywood that will be glued to the block later.
Once both sides were clamped in place I removed the straight edge so it does not end up getting glued too.
While some glue is drying on spars I decided to work on the fuselage rear turtle deck.
Former 3 and 3A were tricky to cut from the RS-59103. They are basically stacked on top one another very close.
I copied the full size templates from the plans and cut them out.
I traced the templates and cut out F-3 and F-3A, stapled them together and sanded the pair until I was satisfied.
While stapled I beveled the bottomed so they will lean at the proper angle.
Separated I layed out the slots for the stringers on F-3A and cut them out.
Making the drag braces was fairly simple. First I calculated the angle to be about 45 degrees.
I nailed blocks into the workbench as directed in the manual so I can move the rear spar sideways to show installing the drag braces. Once installed I push the rear spar against the block to bring the wing square.
About five tries removing a tiny bit of length each time I had a perfectly fitting drag brace. Repeat for each one.
Each drag brace is supported by some gusset blocks made from RS-11. With the miter saw I had these cut in a few minutes.
Once the structure of the spars was completed I drilled the holes for the root and strut fittings.
I made a template like the manual suggested to help locate the fittings exactly and attached the fittings to it.
Then I located the vertical position clamped the fittings in place and drilled one hole.
Installed a bolt into the new hole and drilled the other one.
Once both holes were in place I stapled one RS-561 gusset in place and match drilled the holes.
Then repeated on the other side.
I made sure to label the guests, spars and fittings so I can match them later.
The strut fittings were completed in the same manner just used a different template.
Time to assemble the right wing. First problem was how to put the front spar against the straight edge work the center strut gusset sticking out.
I grabbed some 1/8″ plywood scrap and stapled it onto the spar so I end up with a flat surface to rest on the straight edge.
Next I paced the front spar in place and stapled some blocks to keep it in place.
Used the square to make some reference lines so I can keep the wing square.
Slid all of the ribs onto the rest spar and now I have something that looks like a wing.
Before I can glue anything I need to make the drag braces.