Starting on the Wings

Last Night Connie and I finally started on the wings proper. The instructions from Quad City were a little vague on how the innermost ribs (done first) go on. The two innermost ribs get a sheet of aluminum riveted on top, like two logs across a river supporting a bridge. All the others have a little triangle-shaped gusset at each end.

We began by marking a rivet line on each side of the aluminum sheet and then drilling holes 3 inches apart. We drilled along enough length of the sheet to come within 3" of each end of the rib leaving an overlap for attaching to the forward and aft spars. Then we used the drill press to drill the first hole in one end of the rib, making sure that the rib was perpendicular to the drilling table. We did this by firmly taping it to a piece of PVC piping that was the same diameter as the wing spar (against which it would later lie) and then making sure the PVC pipe was level. Using a drill press is invaluable here. We got straight holes and had the control to avoid the sudden break-through and resulting dent in the opposite side of the small rib tube that a hand drill usually makes.

We laid the rib on the wing, aligning the hole in the aluminum sheet and the rib. The second rib upon which the sheet of aluminum would also sit was placed a few inches apart under the sheet to hold it up and make it perfectly perpendicular to the first rib. Making sure the sheet was straight, we set the first rivet. Then we went to the other end of the first rib and marked the last hole. This was drilled and riveted. Then the middle hole, then progressing outward the entire rib was eventually attached to the sheet of aluminum. The second rib was attached in the same way.

The entire assembly sits on the leading and trailing wing spars very neatly. There is enough aluminum remaining on each end of the sheet to rivet to the spars. Some will have to be trimmed on the trailing edge.

Challenge II: Building an Airplane

Anyone who knows Connie and me know we love to do projects together. As I am a pilot and renting an airplane has gone from expensive to horribly expensive, we decided to try to build an airplane together. I had started on a Cozy a couple of years earlier, but we wanted to get into the air a little faster than the 2 years we are going to need to finish that. I had always liked the Challenger II. With the new Light Sport Rules, I can skip going through the hassle of a medical certificate until the Cozy is done and at 250 hours, it is a fairly quick build. Add to the fact that Connie is a natural at covering aircraft and we could not resist.

We also decided to go whole hog and have a hangar built while we were on the honeymoon. Unfortunately, predictions of a November completion were somewhat optimistic. We took posession of the airplane kit while the hangar was still half-finished and were just able to open the kit in the last couple of weeks. As our hangar contractor has cemented us out of the building for a day or two, filling out the paperwork and restarting this blog just seemed the natural thing to do.

I am putting my logs and pictures at www.klavdivs.com/N3471/N3471.Main.html

We have already finished the tail section, but Connie and I have decided to keep this blog up regularly and so, if there really is anyone out there who cares besides us, more soon...