Outboard and Center Wings Parts Manufacturing

	Construction Time	181.00	hours

Date	Description	Time

03.04.09	Made wing attachment plate (0.064") and bent wing to fuselage fairing	2.50
00.10.03	Made spacers for bell cranks (6V14-3)	1.50
00.10.01	Started to make ailerons bell cranks. (6V14-1)	2.00
00.06.26	Made two additional ribs for ailerons (I am positioning ribs in line with all rear ribs of the wing--got OK from N. Heintz). Formed the two aileron skins.	2.00
00.06.25	Cut aluminium sheet for ailerons.	1.50
00.06.20	Bended two samples for the ailerons. I found that I am getting best results with bends of 20mm, 74mm (or 73mm), 160mm and 330mm. The plans measurements works OK, but the contour of the skin is straighter and the fit more natural with these measures.	0.75
00.04.28	Formed part 6V12-1. Cut L angles for center wing ribs (for walkway). Cut and formed fuel cell skins. I did this at Rejean Houles' school with his assistance.	5.00	Fuel
00.01.25	Made the 10 aileron ribs.	1.50	Wings
99.11.22	Made tip ribs (remaining: straightening). Made riblets (6v7-5).	2.00	Wings
99.11.14	Made parts 6V7-6 and 6V7-7 (splice plates for rear zees)	1.25	Wings
99.11.02	Worked on landing light "kit".	2.50	Wings
99.11.01	I was about to start installing the nose ribs on the spar, but I did not know which one to use at the outboard end of the right spar (is there a landing light at this location). Then, I successfully (this is my second trial) to make front plates for the rectangular landing light brackets. If I use them, there will be one on each side.	2.50	Wings
99.10.31	Cut second spar attachment fron plate. My band saw does not work… I had to use my skill saw.	1.00	Wings
99.10.30	Cut second rear plate and one of the front plates.	2.50	Wings
99.10.28	I drilled out the 15 rivets that need to be replaced and I cut one of the rear plates to attach the spars (the rear plates I previously made were not of the right thickness).	1.00	Wings
99.10.27	Got the wing spars (I had them riveted by another individual). Not being sure of the quality, I brought them to a RAA inspector who happens to have a lot of experience in building metal planes (also). He told me that three rivets needed replacement and 12 others were "marginal".	5.00	Wings
99.10.25	Made two nose ribs for position 950. These ribs have a longer flange (30mm) to be riveted both at 950 and 960. This is because I did not position the holes correctly for the rib outboard of the LE fuel tank. It should have been at 965. The 950 position presented a couple of problems (rivet spacing and not enough space for a rib at 960). After a consultation with Chris Heintz, I will put the rib at 950 and make the LE fuel tank 15mm narrower.	3.00	Wings
99.10.23	I got a compressor and a rivet gun to rivet the spars… First, I practiced on a sheet of aluminium and I started working on the spar after I felt comfortable… different game! The rivets on the spar had smiles and I had to remove most of them (often damaging the hole). Each time I made a mistake, I went back to my practice sheet. For an unknown reason, it is easy on the sheet and difficult on the spar. I decided to outsource this before I ruin my spars (hopefully, the damages I made to this one are repairable).	3.00	Wings
99.10.20	My three spars are now ready for riveting!! Tonight: redrilled holes in left spar that needed to be enlarged (8 #12 holes and one 5/16 hole). Installed L angles and tank supports. Deburred, smoothen, cleaned, primed left wing spar.	3.25	Wings
99.10.19	Intalled 3rd L angle on right wing spar. Made the tank supports (by drilling L angles together. Disassembled spar, deburred, smoothered, scotch brighted, cleaned and primed.	2.00	Wings
99.10.18	Reassembled center wing spar. Pre-drilled rib holes in spar caps of right wing spar. Installed two L angles on spar (I may replace one of them by a U channel to support the LE fuel tank).	1.00	Wings
99.10.17	Cut the rear plates 6V4-6 out of 1/8" 6061-T6	1.50	Wings
99.10.17	Worked on center spar…. installed L angles (except at 1014), deburred, pre-drilled for ribs, filed, smoothered, primed. I was not able to install the L angle for rib 1014… The second rivet hole from the end of the spar is in the way! If you make a spar from scratch, the 33mm distance between rivets should not be between the two last ones, but one more rivet inboard... (this is how the kit is made).	5.50	Wings
99.10.14	Worked on spars. Tried to figure out how L angles are positioned. Doing this, I realized that the pilot holes made at station 960 for the NR rib around LE tank is not good…. too near of the 950 hole (proper location would be 965). I called Zenair and the issue is forwarded to Chris Heintz for analysis.	4.00	Wings
99.10.11	Worked on center wing spar.	4.00	Wings
99.10.10	Drilled the center wing spar caps and doublers + drilled one doubler to the web.	2.50	Wings
99.10.09	Cut rear flange of 6V4-2 to 20mm to ensure that I can drill from the rear side .	1.00	Wings
99.10.03	Drilled and clecoed right wing spar. I also made a much better setup for drilling the spars. I also drilled the 5/16 hole in left spar and I drilled the remaining 3/16 and 1/4 hole (after all, I may recuperate the spar by using bigger bolt and rivets where I made mistakes-- I will check this with Zenair).	3.00	Wings
99.09.30	Scrapped the left wing spar! I drilled the #20 holes and the bolt holes on one side. I also pre-drilled the holes at each rib and L-angle stations. My installation was too "shaky" I ended up with 8 rivet holes not perfect (oversize) and the 1/4" bolt hole clearly oversize. Of course, I could patch all that, but I don't want so many problems on a single part (one or two rivet holes--- I would have figured what to do, but what I have is too much).	2.50	Wings
99.09.29	Finished cutting the spar caps (left wing) and spar cap doublers (both wings). Predrilled the spar web (with spar caps, for left wing).	2.00	Wings
99.08.28	Pre-drilled + deburred holes of left wing spar cap doublers	1.00	Wings
99.09.27	Cut left wing spar caps on angled side (I will cut the other end after having drilled and clecoed the spar caps to the spar web). Also measured and center punch holes on spar caps. I pre-drilled the second spar cap doubler for the right wing.	1.00	Wings
99.09.26	Cut right wing spar caps on angled side (I will cut the other end after having drilled the doublers to the spar (for exact measurement). Also pre-drilled the spar caps with no 40 and deburred. I have one of the four spar cap doublers left for pre-drilling.	2.50	Wings
99.09.25	Finished wing pickups (cut angles+pre-drilled). I had some difficulty with my angle saw and I may decide to do them again (if I don't have time to show them to a friend prior to completing my spars).	1.00	Wings
99.09.24	Made wing pickups 6V4-7	2.00	Wings
99.09.22	Attemped to make holder for landing light. I tried with rectangular automobile auxiliary lignts… I don't like the result… I will most likely go with round lights.	1.50	Wings
99.09.19	Made (cut) various parts (mostly wing parts) using 0.025".	4.00	Wings
99.09.09	Drilled lightening holes in center spar web+smoothen. Flanged all lightening holes in spars. After flanging, the spar is not completely flat.	2.50	Wings
99.09.07	Cut the center wing spar web to proper dimension. I lost a bit of time because I originally made a bad measurement (I had 10mm difference between the two ends). So I had to redo it again. The end result is beautiful. I have about 273.8mm width (the plans call for 273.7). Something sure is that I am well within the 0.5mm tolerance.	1.75	Wings
99.09.06	Filed and smoothen the 6 spar doubler angles (these were 1.5"X1.5X1/8" that we cut into 1.5"X1"X1/8") and the gear slides (1.5"X3/4"X1/8"). Also cut the gear slides to 298mm (8 pieces).	4.50	Wings
99.09.05	Drilled lightening holes in other spar web… filed and smoothen holes (2h). Made wing tip spars (2h).	4.00	Wings
99.09.04	Cut the 2 outboard wing spar webs. I may have to file the web a bit more depending on what technique I use to put the angles on the spars. I also drilled the lightening holes on one of the spars (not deburred yet).	2.00	Wings
99.08.31	I tried to make the edge of my work table straight using the straight edge I borrowed during the weekend. I then made one of the 6V7-11 parts (the wing rear Z). There is a 1mm variation in width of the part. While this may be OK for the Z, I want better than that for the spars. I will try something else tomorrow. Quite a bit of time here has been lost looking for my safety glasses...	2.50	Wings
99.08.30	I started to smoothen the cutted edges of the spar doublers I purchased during the weekend… On two doublers I noted scratches that originally looked innofensive and more like dirt. When I started to sand them, I quickly found that they are much deeper than they originally looked like. I don't know if these doublers are good, but I may have the chance to ask an A&P and inspector tomorrow.	1.50	Wings
99.08.28	When to see A. Létourneau for parts for making the wing spars. He had 1-1/2x1-1/2x1/8 angles that we cut with me to make the 1-1/2x1x1/8 required. We also cut the L angles for the gear slides. I also purchased half a sheet of 0.040" for the center spar web. André lent me a straight edge so I can make my workbench side straight for cutting the spar webs.	1.50	Wings
99.08.27	Finished the four gear box ribs.	1.50	Wings
99.08.26	Smoothered and formed the four gear box ribs. Also cut lightening holes in of the ribs.	2.00	Wings
99.08.25	Final cut of gear box rear ribs. I still have to smoothen, form, etc… I also cut some center wing parts out of the 0.032 sheet.	1.00	Wings
99.08.24	Fernand told me today (and I know he tried several times before) that my gear box rear ribs should be 0.032", not 0.025". He is right. So, I decided to cut everything I need from the 0.032" sheet. I lost quite a bit of time in the process. This is not finished.	2.00	Wings
99.08.23	Cut all NR holes+smoothered+flanged. My hydraulic press needs some repair. Also, when drilling the lightening holes, my chuck fell off the drill press. I reinstalled it, but there was an alignment problem. Think twice before purchasing low cost tools.	3.50	Wings
99.08.22	Cut+formed 4 additional ribs (I now have a couple of spares…we never know). Cut the rear hole on all 26 ribs. Oh yes… more ribs are required compared with the plans because I am going with LE fuel tanks and landing light.	2.50	Wings
99.08.22	Formed 14 wing nose ribs (with cut for spar doubler)	4.00	Wings
99.08.19	Formed 5 outboard wing nose ribs	2.00	Wings
99.08.18	Final cut of 19 nose ribs. Sanded contour+cur corners. I have to file corners and I will be ready to form the ribs.	2.50	Wings
99.08.17	Made a new Nose Rib Master blank (the front portion is kept wider longer). Formed another rib to see the result. It is a bit harder to form, but it will make a better rib (allow for one more rivet). I then cut 19 other rib blanks (rough cut only).	3.00	Wings
99.08.16	Formed a new rib. Fernand gave me a trick to make a smoother, nicer bend of the flange… I start to make the flutes before hammering the flange. The result is much nicer.	1.00	Wings
99.08.15	Made two rib blanks (front) and formed one rib. I think I will make a new master (I cut the front portion of the rib a bit too fast). Also, I don't like the flutes of my fluting tool (I would prefer smaller flutes).	1.50	Wings
99.04.23	Repaired nose rib form blocs (attached new aluminium nose to form bloc and straightened one of the two blocs). Made a master blank for duplication with router.	1.50	Wings
99.04.03	I started to repair the wings nose ribs form blocs today (2h). Those wood made ribs got quite a few good hammer shots in their first life. I made two 1/8 aluminium plates to fit on the nose of the nose ribs (I also removed 1/8 from the rib to insert the aluminium plates. While I could drill the plates by hand (to attach them to the rib, I prefer to wait for my press drill (which is under repair). One of the form bloc also need a small correction in measurement. This will be done later. Finally, while working on adjustment for the bending brake, I made three more L stiffeners. The brake is still not adequate. A previous user will come here next week to look for the problem.	2.25	Wings
99.04.02	Cut 20 strips and made 15 L angles out of that… the main purpose of the exercise is to get used to cutting (now, I am quite good with the band saw and ribbon sander--it took time though) and bending. It appears to me that the bending brake needs adjustment. I will try to call the person who built it.	4.50	Wings
99.04.01	Made one L angle to verify bend allowance calculation and my ability to operate the bending brake… GREAT! The result was perfect (to have a L with a=b=19mm, the developed length is 36.5mm). Then, I tried various methods for cutting the stripes to make L stiffeners. I tried with cisors, but is takes a lot of time and it is not very exciting. I then tried to hand shear a stripe (cut with a knife and bull the stripe), but this does not work well on 0.025". Finally, I tried cutting it with the band saw... WOW! This works well (but it is very noisy... ear plugs are a must). I then measured 30 stripes so I am ready to cut.	2.00	Wings
99.03.27	Finished the work on the three last ribs 6V3-1. I also repressed the other ribs with the 6-ton press to reduce the popping effect. While I did that, I smoothered the flanges of those ribs (the job was done too fast I guess).	2.00	Wings
99.03.26	Smoothened lightening holes and flanged 1 rib. My press broke after two holes.	0.75	Wings
99.03.24	Formed remaining 5 ribs. Drilled lightening holes, deburred holes, smoothened 4 ribs, formed flanges on the four gear box ribs.	4.00	Wings
99.03.23	Filed the 8 ribs a bit more after reading Bingelis (1h). Formed 3 ribs (45 minutes).	1.75	Wings
99.03.21	Drilled holes with press drill (funny… holes are not round) and cut the 8 blanks using a router (1.5 hour). Deburred and cut the 6mm tabs on the ribs (.75 hour). Smoothened rib edges (1 hour)	3.25	Wings
99.03.20	Made rough cut on the remaining 8 rear ribs blanks (6V3-1) that are missing to complete the 20 ribs. These will be the baggage compartments and gear ribs.	1.50	Wings
99.03.14	Flanged remaining holes in the 10 rear ribs). Finished the 12 ribs that I have (verified quality, straightened the ribs, etc -- 1 hour). Tried to draw 6T4.1 on Microsoft Word (1.5 hour)…	3.00	Wings
99.03.11	Sanded more lightening holes… I have only two more ribs to do (out of my 12 ribs). I also reworked the flanges on holes of the two ribs that I flanged. The curve on the ribs is corrected. While this is not construction, I spent about 2.5 hours reading the newsletter this evening...I found some very valuable tricks and mods.	0.50	Wings
99.03.10	Cut the rest of the holes (.5 hour) and deburred (.5 hour). I was visited by a friend who built a similar plane. He lended me some form blocs for the rudder parts and also inspected my ribs. Well, I will have more sanding to do. I also need to make my press for the hole flanging dies out of 26 instead of 24.	1.00	Wings
99.03.10	Sanded lightening holes	1.00	Wings
99.03.09	Drilled holes in the ribs. I completed the 110 mm holes and I have to do the 95mm holes in four of the ribs. I also deburred all the holes I made.	2.50	Wings
99.03.07	I formed three ribs after getting out of bed (1h). Formed 8 more ribs in the afternoon (1.5 hour)	2.50	Wings
99.03.06	Got out of bed at 7am. I formed the flange around my first rib and I also drilled one 110 mm hole. I had problems with the fly cutter I purchased… anyway, I think I learned. The second one will be done much faster. Oh yes, I reworked my flutting pliers... they are very good now.	1.75	Wings
99.03.06	I completed the first rib (two more holes and flange forming on holes. It took me quite a bit of time because I did not know what to use to compress my dies. Also, I was a bit puzzled with the result (rib curved around the holes).	1.50	Wings
99.03.05	Made 8 more ribs out of the rough cut ribs I had. Deburred the 12 ribs. BTW, I purchased the necessary tools for deburring… wow! They are great!	3.50	Wings
99.03.04	Made a master blank (2 hours--I know, I'm very slow). Moved to the garage. Reproduce in four copies using a router and a sandwich with the master blank (1 hour including holes). Deburred (I need another type of file… this one is no good) (1 hour). The trick with the router is fantastic! I cut around four ribs in just 10 minutes with it. It would have taken me about one hour to do the same thing with a pair of snips (and not as good of a job).	4.00	Wings
99.03.03	Rough cut 6 more RR blanks. To do the rest, I need to purchase more aluminium. After making the cuts, I cleaned the remaining of the sheet for future use.	1.00	Wings
99.03.03	Verified measurement from the sample blank that Fernand lent me. One part of it will require a correction. The activities of today do not include the hour or so of testing my flutting pliers (not so good by the way), thinking about how I will make a router table and organizing my workshop (which is now in the furnace room---very small!).	0.50	Wings
99.03.02	Fernand Levesque brought me his form blocs for the HD wing ribs. Great! He also included a RR blank and a completed NR. Verified rear rib form block	0.75	Wings
99.03.02	Measured + rough cut 7 rear rib blanks. I don't have much talent with the aluminium snips! I hope that with practice (rough cut of 20 ribs), I will become better…	1.50