Unintended Adventures

Month: December 2016

I am still building an airplane

It’s always sad when I don’t get a lot of updates posted about progress to the airplane. This semester has been pretty busy.

This is a catch all for all the work we’ve put into the plane since the last update (sometime in October). (Later realized I had a draft from Nov 18, so there may be some overlap here, but I’ll post both of them.)

The right wing has been covered, taped, and patched. It is now ready for paint.

Nothing too exciting else to report there. The process is similar to all the other covering with the exceptions of a few spots that I mentioned in a previous post. I did have the same issues around the tip bow, but this time I only had to use one patch to cover my mess!

The right wing is now covered and riveted. It is ready for tapes, exit rings, and patches. I applied a few things I learned on the right wing to help myself out a bit. The biggest one was the light coat of glue applied to all the sheet metal. This time I thinned down the EkoBond a good bit and brushed it on with a foam brush. This eliminated the bubbles completely and was thin enough not to leave any ridges. As a note, I did babysit it while it was drying since it would tend to get some ridges in it. I would just go back over it and brush it down again and by the time everything had dried I had successfully avoided any problems.

These differences in the wings are annoying, but I figure it’s a good teaching moment if anyone ever call me out on it. Of course I will vehemently deny any sub par covering for a few weeks and then I will give up and discuss it. Maybe EAA can give out awards for the most improvement shown over an airplane build at Oshkosh. Maybe an aluminum, copper, or tin Lindy?

One thing that I really wanted to reiterate is how awesome covering is with a second person. This wing went smoother and it was a lot less of a headache with some extra hands. Placing the plastic strips and tape on the ribs was much faster when I wasn’t trying to hold everything, cut things, and not drop scissor onto my nice fabric while I was working by myself.

(30 h)

Busy Fall

The airplane is still progressing. I voted to work on the plane vs. write an update after each work period.

Since the last plane update, the right wing has had all patches, tapes, and exit rings attached. In addition, the brushed on coat of EkoFill was applied.

The next step is to get the left wing mounted and prepped to cover. This will entail cleaning all the dust and bugs off the frame, applying anti-chafe tape to sharp edges, and getting the fuel cap screws sealed up. Then we will get it mounted into the rotating stand and get to covering.

A few things that I found from last time will hopefully make this wing go better. First is the coat of glue applied to the root skins and the leading edge skin. On the right wing I used a normal brush and I got a lot of bubbles and streaks. This will definitely show through the paint, but I wasn’t too concerned with it since I think it will not detract from the look overall. My options for the left wing are thinning the EkoBond down, using a different brush, or forgoing the coat of glue all together (need to call Stewart’s on this one). Hopefully that will eliminate the bubbles.

The engine monitor project is coming along pretty well. Not much to show at the moment since I’m just coding (very slowly due to a lot of work and school), but I’ve started adapting a configuration file so the limits of the gauges will be configurable. My coding as of now is geared towards the Rotax 912ULS, but I’m trying to keep it as configurable as I can where it is somewhat simple. If this thing keeps moving on and someone else wants to use it with another engine, then I figure we can cross that bridge then. I did find a new source for a lot of bright, industrial screens. They are pricier than the other outlets I found and the smallest screen seems to be 8.4″. Not a deal breaker overall, but I don’t know if an engine monitor needs to be 8″. I found a 6.5″ screen for around $140. It’s not the brightest, but it is close to the requirements I had decided on and some of the soaring community are using it with apparently good results.

(12 h)

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