Relocate Project to Houghton Co. Airport

The project finally out-grew my garage and it was time to move it to an actual hangar.  There I can attach the tail feathers and wings.  Here are some pics from the big day using a 26' long truck.  Everything went as planned with no accidents and mis-calculations on needed truck dimensions.

Root Skins, Fuel Sight Gauge Final Install

Here are acid etched primed root skins.

Following the white topcoat, fuel sight gauges were installed on the inboard side of the root skins (viewable from the cockpit).  After the fuel fittings for the sight gauges were installed, the forward and middle root skins were riveted to the root rib. 

Grommets were installed for fuel fitting, pitot and flap cable penetrations.  The pitot tubes and flap cable run through a third aft root skin piece that is screwed to the root rib for easy removal to facilitate inspection/maintenance.

Here's a closeup of the fuel sight gauge.

Lift Strut, Exit Fairing Fit-up

I trimmed and match drilled the plastic flap and aileron exit fairings to the bottom of the wings and also installed all of the fittings and hardware to the aluminum front and rear lift struts.  The struts are now ready to support the wings when they are installed.

Wings: Root Rib Modification

The aft flexible fuel line from the fuel tank on each wing needs to run under a wing structural member and then over the bottom root rib (and then into the cockpit).  Currently, there is not enough clearance to accomplish this without pinching the fuel line.  Ran's suggestion to work around this situation is that the root rib be pinched to obtain sufficient clearance.  Not the most elegant solution, but better then routing line over structural member which would introduce a high-point in the fuel line and not allow complete draining of fuel tank. 

Using a pair of channel locks and aluminum angle (the latter to distribute pressure on outer side of rib), I pinched the rib until 3/8" fuel line would fit unencumbered.

Right Wing: Ailerons, Flaps, Wing Tip, Gap Seals, Root Skins and VGs

Similar to the left wing, I've got all of the above tasks fitup or installed.

Left Wing: Install Vortex Generators

I completed my last assembly task on the left wing before I move it back on the stand and duplicate efforts on the right wing.  Vortex generators were installed to reduce the stall speed of the airplane which will reduce landing approach speed and likewise reduce landing distance.   I've been told the S7 is better capable to produce 3-point landings with VGs, as well.  The VGs were positioned such that they have the best ‘bite’ at the airflow when the wing is at the stall angle of attack; not too far forward or aft. The manufacturer recommended that the leading edge of the VG be aligned at the 7% wing chord position.   This results in the VG functionally positioned at the 9% position.  The average wing chord for the S7 is 60 inches, so I used 4.2 inches as my setback position from the LE spar. 

Here is a Stolspeed VG

Here are the VGs placed on the precut advesive pads.

It was helpful having the wings off when doing this because then the wing root was exposed.  It was a simple matter of running a string line from LE to TE spar to determine the chord line and then using a triangle square transferring the 4.2" measurement to the top of the wing.  This location mark on the wing was then carried down to the outboard end of the LE spar and a string line run through the two marks.  This line was then projected across the tip wrap area and terminated shy of the wing tip fairing.

Here is the template used to get the correct angle on successive VGs.  The 60 mm template was used for the first 3' on the outboard wing and then spacing was increased to 90 mm up to the wing root.  The manufacturer recommended this placement so that the outboard wing would not stall first and, presumably, not result in loss of aileron control.

Left Wing Root Skins Fit-Up

The root skin consists of three pieces.  The skin is riveted on with exception to the aft piece which is screwed on for internal wing access.  Here are three pieces clecoed together.

I taped the assembly in-place where optimum, i.e. where holes centered on fuel fittings and skin centered on root rib.

 I then transfer drilled into the root rib and clecoed as I went.   I also fit-up the fuel sight gauge mounting bracket.

Here is a closeup.

I'll final assemble after painting.