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K rv
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Date: 11-30-2009
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Number of Hours: 0.00
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Manual Reference:
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Brief Description:
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11/30/2009
Ailerons - 3.5 hours
Yesterday I got some unexpected time in the shop. I was solo, so I couldn't start riveting wing skins, so I decided to pull out the ailerons. I actually started the ailerons just over a year ago, on November 23, 2008. Back on that day I cut out all the stiffeners and shaped them. Yesterday I pulled blue plastic off the skins, match drilled, deburred holes and edges on the stiffeners and the skins, dimpled stiffeners and the skins, and primed everything. Next solo session I can rivet the stiffeners on.
As an aside, I want to emphasize how much work this really is. From one picture to the next above, it may not seem like much has happened, but I spent a solid 3.5 hours working yesterday. There are two ailerons. Each aileron has 8 stiffeners for each face of the skin - two skin faces per aileron, so that is 32 stiffeners. Each stiffener has 7 rivet holes. That is 224 drilling operations. You drill half the holes, then you move clecos to the drilled holes and drill the holes that the clecos were originally in. Installing, moving, and removing clecos is a very time consuming process, and makes my hand cramp - you use a special set of pliers to install and remove clecos. Each edge of each of the 32 stiffeners and 2 skins must be smoothed out. Each side of each hole must be deburred. Since each rivet hole joins two pieces of metal together, that is 4 deburring operations per hole (one for each side of each skin), so 896 deburring operations. Then there is dimpling - the stiffeners can be dimpled with a pneumatic squeezer, which goes pretty quick, but is still 224 dimpling operations. The skins must be dimpled with a C-frame, which takes longer and is more taxing, since you line up the hole, whack with a hammer, move to the next hole, repeat. Again, another 224 holes on the skins. After all that, spraying the primer where two surfaces will mate is a quick and simple process. Let it dry for at least a day, then I can rivet.
12/02/2009
Ailerons - 3.5 hours
Last night I was solo in
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