Covering: Left Wing

After a late Saturday night in the garage, I finally got the left wing covered. First pics show the wing sheet metal roughed up with a scothbrite pad (to enhance glue adhesion) and then the entire wing bonding area cleaned with an acetone solvent. Masking tape was used as antichafe tape and applied to the structure where sharp areas occur. Two coats of U500 glue were applied to perimeter of wing and around under sides of spars, root rib and wing tip. Two thinned coats of U500 were applied to wing sheet metal to prevent "pinholing" following painting.

The fabric was than rolled over the top of the wing and glued down with thinned glue in beads around perimeter. The skin was then slightly tautened to remove wrinkles and skin was glued to sheet metal and to remaining areas on spars, rib and wing tip. Areas of the fabric had to be cutout to fit around ribs underneath. Tag ends of fabric underneath were trimmed off and ironed down.

The bottom panel went on next, first two coats of glue were applied to LE/TE spars. Same procedure went as before, except this time, numerous large protusions existed on bottom of wing such as strut attach plates. The skin was glued on right over these features and after tautening the fabric was sized and the openings were cut for the skin to pass over. I had trouble getting fabric to lay down flat on TE spar as a result.

Both sides were final tautened and complete. Next to the patches....

Covering: Fuselage: Taping

I can't believe I'm finally DONE with covering the fuse. A two week run to Spokane, WA threw a wrench into production. Following are pics of taping the fuse. First couple pics show measuring and marking 2" zone for glue where tape will go and then applying glue along the 2" width.

Next, I lay the tape down and apply a bead of thinned glue down the centerline to secure tape...

This is then followed by gluing down the remainder of the tape with thinned glue across full width of tape. Following drying, the tapes were ironed down, concentrating on getting the pinked edges bonded tight. Some cleanup of glue with MEK was required on skin along taped edges and where spillage occured. Following are completion pics of covered, patched, and taped fuse; top first.

Followed by bottom (dang rudder cable grease rubbed on and through fabric at several spots)

Left side (mosquitos covet this flying machine)...

Right side...

...and the aspiring co-pilot twin little buggers (turn 5 next month) are excited to see something finally resembling an aircraft...

On to the wings....

Covering: Fuselage: Patches

I completed all of the patches on the fuselage. Below are drain grommets and a lexan inspection ring which were glued directly on to the bottom rear end.

Here is the completed section following gluing and ironing of patches. 1" fabric overlap required on all patches.

Rather than tape around the battery door, I glued a large patch over the opening.

....and then cut out the center section and then glued fabric around the inside perimeter opening.

Below are left and then right rear sides of finished patches. The bushings shown are where the horizontal stabilizor will attach. Shown are elevator cable exit ring, rudder cable exit fairings and drain grommets (latter used for routing a cable through, in this instance). Left side has an inspection ring. The rings which are glued down and then patched have the openings cut out later and then plates or hardware are attached. For example the large D-shaped exit rings will later be cut open and a large plasic fairing (similar to the small white rudder cable exit fairing) will be screwed directly into the plastic ring.

Next pic shows the upper fuse behind the cockpit. Lots of patches here because I have the BRS bridles exiting in two locations over the Station 3 cross tube and then further aft at one location over the vertical stabilizor former tube. The bridles turned out to be remarkably thin, so bulges under the fabric weren't too noticeable. Patches also placed over an antenna mount plate and tangs where the skylight will attach later.

Each side of the fuse near the doors has patches placed at corners where wear is prevalent.

Next on to taping the fuse....

Covering: Fuselage: Right Side

The fuse is now completely covered and fully tautened. First, however, are pics of two coats of glue applied to the perimeter of the envelope area and ready for fabric.

Next pics show right panel tacked onto structure with thinned glue.

Finally, pics of completed covered right side from front back views, following trimming and ironing of glue joints. Note the bushings for the horizontal stabilizor are now visible. Slits were cut for them to emerge through the tautened fabric.

Next couple weeks will be spent applying patches and tape, among other things, to the fuse.

Preliminary Avionics Panel Design

Following is a rendering showing my first shot at designing the avionics panel for the plane. As a result of building a tandem aircraft, there is not a lot of space up front for instruments; therefore, included a partial glass cockpit for situational awareness and engine diagnostics plus portable gps for navigation. Eliminating individual gages saved lots of space. Felt more external utility with a portable gps (e.g. backpacking, driving, boating etc., plus potential for XM weather later). Have redundant pitot-driven steam gage flight instruments for backup. Radio and transponder are small round units up top for additional space conservation.

Covering: Fuselage: Bottom & Left Side

I have begun covering the fuse. I started with attaching the bottom fabric panel and then the left side. Took about a week to install each panel. Next will be the right side.

Starting with the bottom, first pic shows two coats of glue applied to the bottom longerons.

Next pic show fabric panel attached and glued to bottom.

Next couple pics show bottom panel trimmed, glued around structure, ironed, and slightly tautened at 250 degrees.

Next the left panel went on. Following pic shows panel clamped and ready for attachment with thinned U500.Next pic shows the panel glued to the outer left side and ready for fabric to be trimmed and glued 3/4 of way around tubular structure.

Next several pics show finished left side tautened at 250 degrees. Note at the battery door opening the fabric had to be cut and wrapped and glued to inside perimeter of opening. In addition, several BRS bridle fabric penetrations (not shown) were needed on the top left side. I decided to reinforce these with 3.5" patches. The bridles were routed over the Station 3 cross member and will be installed below the skylight and fabric to prevent exposure to UV and moisture.

Here are the wings staged on the wing stand I made. Certainly freed up more space in the shop.

Paint Scheme Design

I believe I've come up with my final paint design. The inspiration is from a Citabria that I used to fly in MT. Superflite Matador Red and Insignia White will be combined to create the scheme below. Three view line drawing jpegs were obtained from Rans and brought into AutoCAD, then scaled, traced and hatched. The drawings were useful in estimating quantities of paint product, which will be ordered later this month. I hope to begin painting this Summer.