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BushCaddy ELSA
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Date:  7-18-2009
Number of Hours:  6.00
Manual Reference:  None
Brief Description:  Finished the wing gap seals

I had to finish the lower and top of the wing gap seal on the trailing edge of the wings. I was struggling on how to make it look good and be functional. I first ran the top leading edge wing gap and using my forming tool I curled the end of the top around to the bottom and trimmed off the small piece that stuck out the side. I attached the top at the top gap seal and then ran the bottom gap seal and attached it at the end of the bottom gap seal. I marked the trailing edge with a felt tip marker and cut the excess off. Then I drilled, deburred and riveted three 1/8 rivets in the bottom to make a complete gab seal. Then drilled and installed nut plates for #8 screws to fasten the gap seal in place.

Then I moved on to the area between the stick and the firewall. I used two ½ by ½ by 1/8 angle aluminum and using the existing bolt holes for the control tube cover between the seats I attached the angle at the other end with heavy duty Velcro. I tried my hand at the fabric covering but I think I will wait for my wife’s help there. It did turn out good and will protect the fuel line and the wiring.

I now have 728 hours on this build so far.
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Top gap seal for trailing edge

Top gap seal for trailing edge

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Bottom seal for trailing edge

Bottom seal for trailing edge

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Putting it in place for fasteners

Putting it in place for fasteners

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