Wing tips, lights and polishing

Painted both wing tips, and riveted together the light brackets. Finished two runs of F9 polishing compound on one wing.

painted one wing tip

Magnetometer

Made two small beam like brackets of 5mm aluminium, drilled holes and tapped them for m4 bolts. The bolts will be long enough to hold the magnetometer with 4 m4 nuts. All is stainless (non magnetic). Then RTVd them in place, so the bots can easily be replaced (maybe I will use some that are a bit more aerodynamic). The tips are finally ready for paint.

Nav lights

The brackets for the lights.

Wing tips, nav lights

Finished with the removable wing tips. Started to figure out how to install lights and the magnetometer. The wingtip lights are supposed to be visible from all around, and therefore needs to be mounted vertically. I think I just use some leftover cuts from the ailerons and see how it works.

Wing tips

Tried different ways to get the tip on straight. To position the wing upright, strapping the tip on and using a ruler to adjust, seemed to work OK. The straps with the nuts is to be inside the tip. They are drilled without the tips in place, and they need to be trimmed a bit to make the most fwd hole to fit due to the curvature.

Riveted wing skin, wing tip

Finished riveting on the wing skins. The wing tips will be removable, using the Airward kit.

Ready to rivet on the wing skins

Riveted on all the brackets for the wires. Used m4 A4 bolts and loctite to fasten the clamps. Then I got into problem with the aileron pushrod. The hole in the wing is not at the right place. I had to widen it a few mm to prevent interference. I also had to trim the paddle a tiny bit to prevent interference with the ball joint.

Brackets for wire

Drilled holes in the brackets

Brackets for wires

16 brackets for the wires to the wing tips.

Misc wings

Made all the cover plates and stuff for the wings. Instead of using screws directly on the aluminium plates I mounted nut plates, to be sure they last.

The cover for the aileron counter balance has a nasty design flaw. Two 90 degree bends converge in a single point. It's impossible to make this without the metal cracking. I had to fix one of the covers. Then to prevent this I drilled holes at the convergence point.

Canopy and windshield

Some small trimming around the windshield. Now the canopy can be installed or fitted.

Windshield finished

Sawed off the extra material, deburred and drilled up the holes, and suddenly the windshield was finished. With the airward kit the windshield and the glareshield is now detachable. This will help in case of any modifications later.

Windshield

A bit more trimming, and drilled the holes.

Windshield and fwd bow

I was a bit fast riveting on the firewall windshield strip. Drill out all the rivets and installed screw and nuts (from Airward). Also trimmed the windshield, only the aft bow left, and all the holes.

Windshield

Started with the windshield. Lots of trimming to get this right. The inspector was also here last Sunday. All OK.

New brackets for the wind shield

Left Wing

Finished dimpling and deburring the left outer wing and skin

Left Wing

Drilled all the 3/8 holes including the aileron hinge

More left wing

Left Wing

Skinning of left wing