Airbike Construction Notes
4/11/00
The wing kits arrived today. Both crates had some damage on one end
from a forklift, but everything inside survived fine. We did an inspection
and everything on the parts list is present. TEAM does a great packaging
job and everything is well marked. We had already built a 16'x4' bench
and had materials for the rib jigs. Started building rib jigs.
4/12/00
Finished up rib jig and started cutting wood for the first rib. Finished
first rib.
4/13/00
Pulled the staples from the first rib and did some sanding. The rear
spar pass through is not quite square so I will have to make some adjustment
to the jig. Didn't use enough glue on a few gussets. Must use enough glue
to press out of joint slightly when stapled.
4/15/00
Cleaned up rib jig and made adjustments. Made templates for all gussets.
4/15/00 - 4/21/00
Cut all rib gussets and 1/4" spruce.
4/22/00 - 6/10/00
Glued gussets to one side of rib first. After all ribs were dry, finished
gussets on second side. After drying, all rib cap extensions were trimmed
on the front of each rib. Gussets were sanded around outside of ribs and
inside rear spar pass through. The 1/4" plywood reinforcements were added
to the six ribs supporting the aileron hinges. Pulled the staples in all
ribs.
9/3/00
Resuming work as flying season slows down. Made nose rib routing template
out of 3/8" ply.
9/4/00
Re-made nose rib template out of 3/4" ply. The thinner ply was riding
up between the router bit bearing and the top of the cutter. The thicker
ply works well. Routed eight 1/4" nose ribs.
9/6/00
Rough cut eighteen 1/8" nose ribs on bandsaw. Built up the router
jig to support the router base better around the outside. This prevents
tipping the router and digging the bit into the bottom ribs. Five ribs
at a time seem to work well. All nose ribs finished except for the slot
for the leading edge stringer.
9/30/00
Made 1/4" nose rib template out of 3/4" ply. Rough cut 14 1/4" nose
ribs.
10/1/00
Made 1/8" aileron nose rib template out of 3/4" ply. Built router
support jig for nose rib templates. Drilled hold-down holes in the 14 1/4"
aileron nose ribs.
12/9/00
Rough cut 20 1/8" aileron nose ribs using correct template. Used templates
to router all aileron nose ribs. (20) @ 1/4" and (14) @ 1/8". Finish sanding/filing
all remaining rib gussets. Made all 1/8" (4) root and tip rib solid ply
end caps.
12/10/00
Glued solid ply end caps to two tip ribs. Pulled staples on first
two tip rib end caps. Glued remaining end caps to root ribs. Trimmed ply
end cap on first two tip ribs.
12/11/00
Cut and sized aileron hinge bearing supports for root and tip hinges.
Cut and glued center aileron ply spacers for bearing brackets.
12/14/00
Pulled staples in remaining 2 rib end caps.
12/23/00
Finished fabricating 4130 aileron bearing support brackets (6). Trimmed
trailing edge of all ribs to 46". Made first aileron end cap from 1/16'
ply. Rough cut remaining 3 end caps for ailerons.
12/24/00
Finished fabricating remaining 3 aileron end caps. Drilled 1/4" hole
in all aileron end caps for hinges. Glued aileron end caps to root and
tip ribs. Glued 1/4" aileron nose ribs to root, tip and #5 ribs. Built
jig for main spars (both in one jig). Sized and cut all RS-5 and RS-9 spar
verticals for main spars. Cut 12" RS-7 spar cap extension for wing tips
(4). Cut root RS-9 doublers and RS-8 diagonals.
12/25/00
Pulled all staples from root and tip aileron end caps and #5 ribs.
Made RS-11 diagonals for main spars. Tapered RS-7 doublers for main spars.
Made RS-7 doublers for spar cap splices on main spars.
12/26/00
Built and bolted down wedge clamps. Laid out wax paper, clamps and
blocks for gluing. Glued both main spars.
12/30/00
Sized and cut shear webs for main spars. Glued and stapled shear webs
to both main spars.
1/1/01
Pulled staples from main spar shear webs. Light block sanding of main
spars.
1/7/01
Cut all verticals and diagonals for rear spars. Cut RS-7 doublers
for both rear spars. Reset jig for rear spars and fit all spar pieces.
Trimmed remaining 2 rib end caps and all aileron end caps. Rough cut root
and strut attach brackets and aileron horns from RS-100.
1/13/01
Moved wedge clamps for rear spar jig. Glued up both rear spars.
1/14/01
Removed rear spars form jigs. Block sanded rear spars. Cut and fit
RS-53602 ply shear webbing for both rear spars. Glued RS-53602 ply shear
webs to one rear spar.
1/20/01
Glued RS-53602 ply shear web to remaining rear spar.
1/21/01
Removed rear spars form jigs. Disassembled wing spar jigs. Pilot drilled
root fittings, strut fittings and aileron horns. Finish drilled root fittings,
strut fittings and aileron horns. Shaped ends on all fittings and aileron
horns. Deburred and finished root fittings, strut fittings and aileron
horns. Glued RS-9 aileron hinge support to all 4 end and root ribs.
1/22/01
Made bushings for all aileron hinges. Drilled and assembled aileron
brackets for end, root and #5 ribs.
1/25/01
Sanded bottom edges of ply webbing flush on all spars.
1/26/01
Block sanded rear spar ends. Polished all aluminum brackets. Built
fixtures for cutting bevels on top of spars. Setup and cut bevels for front
spars. Pulled webbing staples from rear spars. Setup and cut bevels for
rear spars. Trial fit ribs on spars of left wing.
2/3/01
Cut and fit all RS-561 doublers for attach fittings. Glued all RS-561
doublers for strut attach fittings.
2/10/01
Drilled all spars for root and strut (1/4" bolts) attach fittings.
Attached 21/2"x3/4" reference board to table to locate front spars. Clamped
front spar (left wing) to reference board and bench. Slid all ribs on rear
spar to begin left wing assembly.
2/11/01
Cut doublers for root and #1 ribs for wing attach brackets. Glued
doublers on root and #1 ribs. Glued RS-561 ply doublers on root of both
left spars.
2/15/01
Cut and fit reliefs for RS-561 ply and root attach brackets, in root
and #1 ribs for left wing. Reamed root attach fitting bolt holes in both
spars (clean-up from gluing doublers).
2/16/01
Set brass nails in all ribs - left wing. Glued all ribs to both spars.
Drove brass nails flush.
2/17/01
Cut and fit RS-9, RS-8 and RS-7 anti-drag diagonals for left wing.
Cut RS-561 gussets for anti-drag diagonals. Cut and fit RS-11 gussets for
anti-drag diagonals. Glued all parts for anti-drag diagonals for left wing.
Cut and beveled (36) trailing edge gussets. Cut slots in root ribs for
fuel level viewing. Glued (9) trailing edge gussets to bottom of ribs,
left wing.
2/18/01
Cut and fit RS-15 trailing edge for left wing. Marked rib positions
and glued RS-15 trailing edge to left wing. Cut and fit RS-653 aileron
spars for left wing. Positioned and glued aileron spars to ribs on left
wing.
2/19/01
Trimmed and sanded RS-15 trailing edge on left wing. Fit root and
tip ribs. Trimmed and sanded aileron spar. Cut and fit RS-3 aileron spar
caps. Glued aileron spar caps. Varnished tip and root ribs and rear spar
shear web (left wing).
2/21/01
Glued root and tip ribs to left wing. Cut and fit RS-1 aileron diagonals
(top). Glued top aileron diagonals. Glued midpoint of anti-drag diagonals
to ribs (left wing).
2/22/01
Cut and fit RS-7 and RS-8 fuel tank supports on left wing. Glued RS-7
and RS-8 tank supports. Cut, fit and glued bottom RS-3 aileron spar cap
pieces (left wing).
2/23/01
Cut, fit and glued RS-1 bottom aileron diagonals. Marked position
for aileron nose ribs. Glued aileron nose ribs. Glued top trailing edge
gussets. Sanded aileron RS-3 spar caps flush with ribs (left wing).
2/24/01
Glued RS-5 lower compression members on left wing. Glued 1/4" aileron
nose rib doublers at #4, #7 and #10 ribs. Cut aileron free of left wing.
Shaped aileron rib caps to match nose rib curve. Sanded all trailing edge
gussets smooth. Block sanded aileron spar caps, rib caps, end caps to match
nose ribs. Trial fit aileron hinge brackets and hardware.
3/1/01
Varnished left aileron.
3/2/01
Varnished left wing.
3/3/01
Glued upper RS-5 compression members to left wing.
3/6/01
Removed left wing and aileron from bench. Fit all ribs except root
and tip to right wing.
3/7/01
Cut, fit and glued 1/4"sq doublers on root and tip ribs for attach
bracket clearance (right wing). Glued RS-561 root attach doublers on both
right spars.
3/8/01
Cut reliefs for root fittings in rib #1 for right wing. Pre-set brass
nails for ribs. Glued all ribs to both right spars.
3/9/01
Cut RS-11 gussets for right wing anti-drag diagonals. Cut and fit
RS-9, RS-8, RS-7 and RS-561 parts for anti-drag diagonals. Glued all pieces
for anti-drag diagonals for right wing. Glued bottom trailing edge gussets
for right wing.
3/10/01
Cut fit and glued RS-15 trailing edge to right wing. Repaired #2 rib
break aft of rear spar.
3/11/01
Cut, fit and glued aileron spar to right wing.
3/13/01
Cut, fit and glued RS-3 aileron spar cap pieces to right wing.
3/16/01
Cut, fit and glued RS-1 top aileron diagonals to right wing.
3/17/01
Cut fit and glued RS-3 bottom aileron spar caps to right wing. Cut
fit and glued bottom anti-drag diagonal gusset. Glued anti-drag diagonals
to midpoint ribs. Finished bottom repair of #2 rib.
3/18/01
Cut, fit and glued RS-1 bottom aileron diagonals for right wing. Cut,
fit and glued top RS-5 compression members to right wing.
3/20/01
Airframe, completion and engine mount kits arrive. Full inventory
and trial fit of fuselage halves and landing gear struts.
3/23/01
Glued root and tip ribs to right wing.
3/24/01
Beveled top aileron spars for right wing. Cut, bent and shaped 1/4"
steel wing-retaining pins. Trial fit left wing to fuselage. Glued bottom
RS-5 compression members to right wing.
3/26/01
Cut, fit and glued RS-7 and RS-8 tank supports for right wing.
3/27/01
Glued aileron nose ribs to right wing. Glued remaining trailing edge
gussets to right wing.
3/28/01
Uncrated new Hirth 2702. Full inventory of parts.
3/30/01
Fit right wing to fuselage.
3/31/01
Cut, fit and glued upper RS-5 fuel tank compartment reinforcements
to right wing. Cut right aileron free of wing. Shaped aileron rib caps
to aileron leading edge. Sanded trailing edge gussets. Wired brushed and
filed welds on front fuselage half. Cleaned front fuselage half with AFS
high strength cleaner (10:1 mix with water). Applied AFS steel conversion
coating to front half of fuselage (foam brush - bad idea).
4/1/01
Cleaned up glue joints on upper tank supports for right wing. Sanded
front fuselage half to get rid of bubbles formed by foam brush. Re-applied
conversion coating by wiping on with a clean rag (worked like a charm).
Wire brushed and prepped rear fuselage half. Ground excess plate flush
around tailwheel mount. Cleaned rear fuse half with AFS cleaner. Applied
AFS conversion coating to rear fuse half (wiped on).
4/4/01
Cut (18) RS-1 verticals for 1/8" nose ribs. Glued RS-1 verticals to
1/8" nose ribs.
4/8/01
Cut and fit (2) RS-5891 play tank floors. Cut and fit RS-4 members
for tank floors. Cut and fit RS-5 tank cover support for rib #1 on right
wing. Cut and fit RS-5 tank cover support for rear spar on right wing.
Made (2) RS-672 1/4" ply aileron nose ribs for rib 5a on both wings. Cut
off 1/4" of (4) 1/4" ply nose ribs for doublers on ribs #5 and #9. Cut
and fit RS-1 sticks for (2) root nose rib and (2) tip nose rib doublers.
Glued #1 rib and rear spar RS-5 tank cover supports on right wing. Glued
RS-4 members to both tank floors. Glued 1/4" ply doublers on #4, #7 and
#10 aileron nose ribs. Glued 1/4" ply doublers to 1/8" ply nose ribs at
#5 and #9 on both wings. Glued RS-1 sticks to root and tip nose rib doublers.
4/9/01
Sanded upper tank support members flush on right wing. Filed and sanded
all nose ribs to clean up glue squeeze out. Cut slots in all nose ribs
for RS-4 stringer.
4/10/01
Glued 1/4" RS-1 reinforcement to #5a aileron nose ribs. Splice both
RS-4 leading edge stringers. Glued RS-1 diagonals in both root and tip
aileron bays.
4/13/01
Cut relief in root nose rib for root attach bracket. Glued all nose
ribs to right wing. Glued RS-4 LE stringer to right wing nose ribs.
4/19/01
Primed all aluminum wing brackets. Primed rear half of fuselage.
4/21/01
Sanded one wheel pant. Varnished right wing LE stringer, nose ribs
and spar. Varnished right aileron LE ribs and spar.
4/22/01
Profiled al ribs and nose ribs on right wing for LE ply sheet. Built
form for LE ply sheet. Built (2) wheel pants brackets. Drilled brake back
plates for axle plate bolts. Made (2) 1 7/16" axle spacers. Made (2) arm
brackets for LG brake cable adjusters.
4/23/01
Cut RS-516 LE ply for right wing center panel. Put RS-516 LE ply into
form. Positioned landing gear legs on fuse and drilled 3/16" holes for
retaining bolts. Bolted on gear. Cleaned up vertical stabilizer. Trial
fit vert stab and rudder to airframe.
4/25/01
Varnished front or right LE spar. Varnished inside of right wing center
LE ply. Made and pressed control stick pivot bushing into place. Slotted
center LE ply for strut attach brackets. Glued center LE ply to right wing.
Drilled 1/16" holes in wing retaining pins for safety pins.
4/26/01
Pulled staples and clamps from center LE ply. Sanded off excess glue
and fit LE ply slots for strut attach fittings. Cut and fit root LE ply
for right wing. Placed root LE ply in form. Cut our LE root and tip rib
inspection/access holes.
4/27/01
Masked and varnished root LE ply for right wing. Bolted root and strut
attach brackets to right wing (permanent). Cut and formed tip LE ply for
right wing. Primed all wing attach fittings and some of fuse. Glued root
LE ply to right wing.
4/28/01
Removed staples from root LE ply on right wing. Sanded joints and
cleaned up glue. Masked and varnished tip LE ply for right wing. Glued
tip LE ply to right wing.
4/29/01
Removed staples from tip LE ply on right wing. Sanded joints and cleaned
up glue.
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