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Sonex 815 Build Logs
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Date: 1-14-2007
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Number of Hours: 2.00
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Manual Reference:
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Brief Description: Install leading edge skin
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Continued working installation of LH leading edge skin. Spent over an hour tucking and un tucking the lower edge of the skin including installing and removing the tension straps and wood spacers. This is because when the lower aft skin is un-clecoed from the spar, the wing can twist (which of course it did by my not realizing this would happen). So I got the leading edge skin where I wanted it, drilled through the lower skin, and didn't hit a spar hole. Figured out how much to block each end of the aft spar to get the spar hole to line up exactly with the lower aft skin (if I didn't drill a few experimental holes, this requires x-ray vision). First time this happened, I figured I would un-tuck the LE skin, block up the aft spar until straight, then re-tuck. Of course the tucking process was un-doing my blocking process, and the #9 rib decided to grab the LE skin lower edge (which is still 3/4" too long from the bending process) and bend it between the rib and main spar. This left a "lump" in the tucked skin, and I figured what was wrong. So I had to un-tuck it, use the hand seamer to bend the skin edge back flat, and re-tuck it. This tucking isn't easy. I'm working with the wing over my head, spar on the very edge of the sawhorses, basically with the whole wing about to fall on the ground. Pretty nerve wracking. (Especially when the cross-beam of one of the sawhorses decided to let go causing the two halfs of the sawhorse to spread wider and wider - I almost lost it there.) But after this, I had a few experimental holes to look through to get the blocking right, so I got that, then drilled the holes along the spar. Now probably will turn the wing over to drill from the spar forward onto the ribs. This should work out because I put a reference line on the skin where the holes should be (I'm not worried about working from the front aft here, it's so close I could't get it any better anyway). This must be one of the most frustrating processes to date, but ultimately progress was made.
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Straps on top, boards on the bottom.
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Boards in place to pull on lower skin. Probably better to invert this whole set up.
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Showing line on LE skin at spar tip.
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