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Nigel & Nicks RV-7
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Date: 11-5-2017
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Number of Hours: 2.00
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Manual Reference: AeroSun-Vx_Wingtip
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Brief Description: AeroSun VX Wingtip Installation
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1.1 - Using either the full-scale print out of the mount template sheet or the optional Template Jig (shown below); locate the Right wingtip and Right Template (09-2500-R).
1.2 - While pressing mount template firmly against the intersection of the aft and lateral faces of the wingtip, locate template so that all four gage windows have roughly an equal reveal. Also, use the forward gage window to align the jig with the leading edge of the wing.
1.3 - Once properly located, hold the jig in-place with one hand and use a Sharpie Fine Tip pen to locate the center of one side of the Mount Holes.
1.4 - Using an 1/8” drill bit, drill the marked hole
1.5 - Using a 1/8” Cleco, fix the template to the new hole. Ensure the template is pressed against the rear bulkhead and is aligned parallel, then mark and drill the other Mount Hole, then Cleco the second hole to fix the template in-place.
1.6 - With the template securely held in-place with the two Cleco’s and gently pressing down on the front, top edge of the template, use the Sharpie pen to carefully trace the inner perimeter of the template cutout section.
1.7 - Remove the template to reveal the traced line.
2.1 - Using die cutter or Dremel tool and a 1.5” diameter cutting wheel, cut to the INSIDE of the traced line. NOTE: Be sure to leave the traced line visible and only cut up to it, since final fit and finish will be done via the sanding process and final fit.
This stepwas pretty straight forward. Lots of dust - need mask. Note: Don't do this on the back verandah - wives get upset.
2.2 - Using a 80-150 grit ½” sanding drum attachment, smooth the cut edges and corners while being diligent to keep inside the marked lines. While sanding, keep the tool aligned with the foreword section (in plane) of the wingtip (i.e. keep tool axis inline with the forward direction of the aircraft).
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Template in place
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Initial cut
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Dremel used to sand closer to outline
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