Right Wing Rear Spar and ER Tank Access Panel

Well, today was a big day in the garage, made possible by my new garage fan! It was still pretty hot, but the moving air made it bearable.

I started by finishing the prep on the rear spar and getting it riveted to the ribs. After that, I right-sided the spar and got to countersinking all the skin attach holes.

Those countersinks need priming, though, I think that’s in a few photos down.

I have no idea what this picture shows, but I guess I’m ready for skins.

Maybe it’s just that I’m ready for priming the spar flange…

Yup, that must be it. Here’s the spar flange primed.

Love this self-etching primer. 

It’s time for skins. A long time ago I edge-finished, dimpled, and primed the main win skins (and the wingwalk doubler). This photo shows that I’m remembering to put the wingwalk doubler underneath the top main wing skin.

Pretty skins.

And after a few (many) clecos, both top main skins (on the right wing) are on!

That’s a lot of clecos.

I threw both right wing tanks on the spar and screwed them down with about every other #8 screw. The wing was perfectly aligned at this point, and I decided to use the now-useless leading edge skin to fabricate what I’m calling the ER tank access panel. The dremel helped me get close, then I used a file and a scotchbrite wheel to edge-finish.

This is the general idea.

Now I just need to figure out how to find the holes for the #8 screws on the outboard side of the inboard tank.

To do that, I needed to prep the interface strip. Here’s the strip with some #8 nutplates halfway-riveted.

I think there were 14 nutplates, so 28 rivets.

I’ve just set the outboard strip into the gap. You can see where the #8 screw dimples will align.

This is the fun part of building.

Here’s the inboard interface strip installed (we’re looking at the bottom of the right wing.

Now let’s move to the actual access panel.

So this ~4.125″ piece was cut from the right leading edge. I put the skin under the outboard skin, but clecoed it to the inboard skin, and used my sharpie for a “perfect” line.

Then snip snip snip and file file file.

Then a trial fit.

Dang. There’s a little more of a gap than I want. But I’m going to massage it into the middle of the gap and it should look fine.

I was disappointed at first, but massaged the #40 holes a little, and the gap looks a lot better. I think there are some more pictures tomorrow.

Long day. 4.0 hours. 2.0 on the spars, 1.0 on the wing in general, and 1.0 counted against the ER Tanks.

45 rivets on the rear spar, 18 rivets on some of the ribs to main spar, and 28 rivets on the right wing’s inboard interface strip.

And some blood. Don’t forget to edge-finish, folks.

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Author: Andrew

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