Started 01/22/2006 finished 07/09/2006 Hours worked this
chapter : 96.0 Holding off on the last step of installing the spar into the
fuselage until the wings are finished and time to build the fuel strakes.
Installed engine hard points 01/01/08
Here
you can see the Jig made out of practical board, I used hot glue to hold it
together during construction. On the jig is some of the spar foam rough cut.
Both top and bottom foam are set against the back of the jig to which you
sand them down so they match.
I
used my dermal with a 1/8 rasp carbide bit set to the proper depth. Then I
cut groves in the area to be removed. From that point it was simple to sand
down until all the groves are removed and smooth.
Here
you can see the finished end.
Here
the top foam and the forward are macro together. I used stick pins to hold
the foam in place until cure. I don't use finish nail that much, I
think it is kind of over kill sometimes, that not to say I never use nail
only when needed.
All
three side macro together, I used tape and pins to hold until cure.
Glassed
inside with bulk head and hard points installed too.
Outboard
hard points
Inboard
hard point, the 1 inch whole in the bulk head will allow wire to pass later
on.
CS4
foam cut and fitted.
CS4
inside glassed.
CS4
micro in place, pined and weighted down for cure.
Cut
and sanded the spar cap trough, in the picture you can see the sanding block
I made out of MDF.
In
this end view you can see the small twist in the end part of the right hand
spar cap.
Sheer
web lay up with the hard point visible. The glass was cut on a taper from 12
inch wide to 14 inch wide on each end, the center section glass was cut
strait at 14 inch wide. This is possible because I use a cutting wheel
on my glass cutting table to make the cuts.
On
the glass cutting table I clamped my s-glass roll dispenser. To keep track
of the layer I use a sheet of paper with the length and sequence number, as
I started each layer I crossed it out, simple and it worked. I have the
correct number of layer as called for in the plans, although you can be a
few more or less.
Glassed
with peel-ply waiting for cure. In the picture you can see the rats nest of
cross threads removed during lay-up. The jig with sand bags served as
a back stop to keep the spar from moving during this step, foam scraps kept
it level.
In
this shot you can see the length marking on the plastic tape and garbage bag
I used to protect the foam.
Same
thing on this side just different number of layers and lengths. Take your
time it will go just fine. Plan for about 6 hour minimum per side.
Wood
blocks inserts seat belts hard points.
Three
sides glassed waiting for cure
In
this shot you can see the peel-ply where the wing mounting hard points will
go.
Out
board external hard points.
In
board external hard points
Access
holes cut and last side glassed.
Trimmed
the glass in the two openings and the two ends. Cut the two 2 1/4 access
holes at each out board hard point. After cure I hung spar up with the
canard wing to wait until needed.
Spar
finished waiting to be installed.
Installed
engine T2024 hard points before main spar installation. (01/01/08)
Finished, installed spar in fuselage during Chap 15 Firewall build.