983RV Life

Category: Wings

  • Finished Right Flap Deburring and Reassembly

    Finished Right Flap Deburring and Reassembly

    I got all of the parts deburred for the right flap and put all of the parts together in preparation for when the replacement parts show up. I just need to drill those two holes and deburr the one nose rib and then I can get the right flap dimpled/countersunk, primed and assembled. I countersunk the attachment brackets on the rear side but I still need to countersink the trailing edge insert. Trying to keep progress moving while I’m waiting on shipments. It will not for sure be a week before I can post again as we are leaving tomorrow morning.

  • Flap Drilling and Deburring – Day 1

    Flap Drilling and Deburring – Day 1

    I got all of the ribs drilled. Luckily the holes were all final sized already. There were just the two holes on each nose rib that were non-existent that I had to drill. Unfortunately I found another issue with a rib while I was deburring it. It was cracked where they had folded it during manufacturing. So I ordered another one of those which hopefully they will arrive while I’m in Mexico so I can get back and get started right away. I need the parts so that I can get everything primed and put together. I was going to finish one of the flaps but that broken nose rib put a stop to that. That is it work wise until I get back from Mexico.

    Edit: I went back out and did two more hours of deburring. Might as well get parts deburred that are going to need it anyways. Gotta keep the assembly line moving!

  • Left Tank Leak #2

    Left Tank Leak #2

    After I fixed the two leaks that were near the gas cap, I went to pressure test it again and I had three leaks near the fuel level sender! I pulled the fuel level sender off and looked in and the bead looked just fine, which is the crazy part. So I attempted to seal it again using a longer popsicle stick which ended up making a mess…. I’m really not happy with how this turned out. I should have done the syringe like others had done. I got a chance to try that though because my attempt to seal that area up only sealed one of the three holes. The other two were still there. So I used a syringe this time to get it more precise, and that worked way better. I’m waiting on the sealant to cure before I test for the third time. Luckily the other tank was good to go and I installed it on the wing.

  • Flaps Initial Assembly

    Flaps Initial Assembly

    I got the flaps fully assembled tonight. It took a bit because they are just so stinking long. I don’t have a table long enough for them to fit on really so I might have to figure something out before I verify they are match drilled. I can only hope they are already final sized like most of the other wing components have been. That would help me out a ton. I do still need to match drill the bracket holes and it looks like my parts will be arriving the week I am gone to Mexico so I’ll have to finish that one flap up when I get back. Not really sure if I’ll be able to finish one flap this week or not since I am going to Branson for a cousin’s wedding on Friday and Saturday but I will try to get as far as I can without rushing.

  • Tank Tests – One Good One Bad

    Tank Tests – One Good One Bad

    The first thing I got to was the tanks. My testing kit arrived and I got it all setup. Luckily the right tank did not have any leaks, but the left tank had two. But luckily those two leaks were right near the gas cap so I was able to reach them with my finger. I got them sealed from the inside and then I put a little on the outside that I will scrape some away later after it cures. I put a tiny bit of pressure on it so that it could push some of the sealant a little bit deeper into the leaking passages and I’ll leave it like that over night. It should be enough pressure to push some sealant in but not enough to blow a hole through it since that sealant is so thick.

  • First Day of Flap Building

    First Day of Flap Building

    I got quite a bit of the initial work done on the nose ribs and brackets. I did make one mistake that I’ve ordered replacement parts for. The drill press caught the part and forced it off the table and up the drill bit, which elongated the hole. Unfortunately it elongated it WAY too much and this is a critical area where the control bolts will bolt through and I can’t have that. Hopefully the new parts arrive soon or at least while we are gone to Mexico. But I got all of the parts at least cut and match drilled for initial assembly tomorrow.

  • Tanks complete and ready for pressure testing

    Tanks complete and ready for pressure testing

    I got the rest of the 40 rivets set and I drilled and dimpled the screw holes on the edge of the skin. Now I just need to let these sit for a few more days to make 100% sure they are cured and hopefully the pressure testing kit will arrive soon. Next step is the flaps!

  • Tanks Fully Assembled (Almost)

    Tanks Fully Assembled (Almost)

    The rear baffles and Z brackets have now been installed on both tanks! I’m so glad that part is done and I can’t wait for my test kits to arrive so I can verify they are 100% sealed. I know the front half is sealed so now I just need to verify that the back half is sealed. It looks very promising from the little I can see into the tank from the fill hole. Tomorrow I will remove the few clecos that are in it, countersink those holes and then install rivets, and then I will dimple the screw holes along the edge that are marked to be dimpled. Then they will be 100% complete and ready to install after pressure testing. Fingers crossed that they don’t.

  • Leak Testing Completed Successfully and Fuel Return Port

    Leak Testing Completed Successfully and Fuel Return Port

    The leak testing was successful apart from the caps and the seal I did on the fuel vent line. With those fixed it did not leak anymore. I went ahead and installed the fuel return ports so that I can have it there when I finally make my decision on the ignition/fuel system type. I also did one last look through and cleaned the tanks thoroughly so I could seal it up tomorrow.

  • Leak Testing Before Closing Tanks

    Leak Testing Before Closing Tanks

    I felt it would be prudent to test the tanks in their current state for leaks. There are different ways everyone has done this but I’m just going to do water for now. I filled them up with water and the only leaks I had was my tape job trying to close off the vent line (which I replaced with an aluminum tube going above the water line) and the gas cap (which I just had to tighten it down so it would clamp down harder). So far so good! It seems to be holding water for now. I’m going to give it a couple of days so I can try to rest my leg and get my mobility back.