Monday, September 10, 2007

Stopping by for another photo shot. Looking back at my 2 weeks in KL, much has been achieved though more should have been done if not for my mistake in not bringing my drill bit set over. I will be back for more!
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Another repeat for the upper inboard skin.
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Repeat this process for the upper center skin. Note, at this point in time, the spar cap which should not be placed underneath the aft spar has already been drilled without my knowledge then.Sigh again!!
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Seen here in this photo, i drilled and clecoed the outboard main upper skin to the left wing aft spar at few places ,followed by one place /rib in the aileron cove.
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Btw, i did not follow the manual w/reg clecoing a scrap aluminium in order to clamp the main skin tightly on the leading skin (which i find it unnecessary). Here, using #40 bit again, i drilled and clecoed the skin to the main ribs in three places .
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The outboard upper main skin was placed in position and drilled at its front spar after alignment check.
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On a hindsight w/ regd to the spar cap mistake, the cue to trim the main rib to accommodate the cap (something not mentioned in the manual) should have triggered me to stop and think abt what i was doing in order to prevent such blunder. Anyway, past is past. Will learn to be wiser from now on..
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Looking back on this photo, i now realised my mistake in installing the spar cap for the aft spar. Note: they are only meant for the front spar. Can only salvage the undrilled cap clamped on the lower flange of the aft spar. As for the cap already drilled at certain places on the aft spar, i doubt it could be salvaged. Worst come worst, i will fabricate another one. Sigh... all in a name of lesson learnt.
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Cutting and especially filing the spar cap for the left wing seemed forever.
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And of course the inboard leading skin as well...
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Same goes to the center leading skin..
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Clamped and tightened with afew nylon strap and w/ alignment checked, i started to drill the outboard leading skin to the left wing front spar.
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Clamped and tightened witha few nylon strap and w/ alignment checked, i started to drill the outboard leading skin to the forward spar.
Clamped and tightened with a few nylon straps plus w/ alignment checked, i started drilling the outboard leading skin to the front spar.
Close up view of the front ,aft spar and ribs w/ all #30 rivet holes drilled looking inboard
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With the outboard leading skin of left wing tightened with a few nylon strap and clamped in position ( alignment checked as well), i started to rivet the skin to the forward spar.
Close up view of the left wing front spar assembly looking inboard.
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With all #30 holes drilled on rib/spar assemblies.
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Taking time to take the famous V sign photo..Note the digital leveler i used frequently to check for true alignment in between drilling as well.
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Happily drilling holes with limited space available due to my dad's water filters.
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The appropriate five rivet holes already drilled. This prominent station is at STA 69.0 due to the back to back main ribs fitting.
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Five rivet holes drilled with #30 bit as instructed by the manual at a station on the left wing front spar.
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All the leading edge and main ribs between station 33.2 and 144.95 would need five #30 holes while the rest require only three each. For convenience sake, i have marked down all stations along the spar.
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Tadah!!
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Drilling the rivet holes of the aileron cove rib 1 through the aft spar while being clamped against flap cove rib 14.
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Result of an hour plus of cutting and breaking a few Dremel cutting wheels.
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