Monthly update - Started working on Bottom Skins

Project status for now:

- Control surfaces are complete - I do have the parts to build another aileron and most likely will do so later in the project. I may be able to salvage the one I have, I just wasn't happy with the trailing edge. EDIT: I did end up building another aileron I was happy with later on

- Tanks are complete and have been mounted

   I did run into an issue on the left wing where the skin mating between the tank and the leading edge is quite tight. I am going to remove the left tank and file down the skin a bit to create a little more of a gap. The scotchbrite wheel on a die grinder will come in handy for that

- Wing wiring is complete. That section appeared more difficult than it actually is. Once you get started and understand what they are asking you to do (Insert molex pins into connectors, etc) then things move quickly. One thing to note is that there are a few wires which are different colors than the plans show however I believe I got the correct wires in the correct connectors :)

- I am fairly certain I will be going with Garmin Avionics for this plane, and there has been quite a bit of discussion about the use of the ADAHRS mount that comes with the plane and it's suitability for Garmin vs the original design which fits the Dynon. I am going to build and install it anyways assuming things will work out.

- Had a scare on the j channel for the bottom wings. One of the first steps in Chapter 13 for the wing kit is to match drill the j channel by using the wing spar as a drill guide. I remember originally messing up which was right and left and sure enough much later in the project this came back to bite me. It appeared to me that the holes were not lining up correctly. I even wrote vans support, however I realized after the fact that I had reversed which was which. I clecoed them on the skins and things did line up.

This weekend hopefully will include lots of deburring (Edge and hole), priming, and dimpling. Once that is complete it will be on to the actual riveting of the skins. I have multiple helpers lined up unlike what happened on the top skins.

Tanks complete

The excitement got the better of me, but I do believe my tanks are leak free. The true test will be with fuel some time down the road (a long time) but I am proud that I was able to produce leak free tanks without the need for opening up the baffle.

One thing I attribute this to besides absolute dumb luck (there is some of that as well) is that I did not spare the proseal, and did not make an attempt to do the prettiest job.  While I was building I often would go on VAF and see the photos of people's tanks that looked pristine and think to myself that I somehow was doing an inferior job. Because I was liberal with the proseal, and did not try to thin out the sealant on every seam to look nice, the results were very pleasing here.

Still here, still plugging away

This summer has been filled with family trips and house projects so the building slowed down unfortunately.

I finally have the tanks in the driveway, and am starting to leak test. So far the results are quite positive but I am having the same difficulties that most people have sealing the filler cap, as well as some of the fittings on the inboard side. Once I fix that, I believe (hope) I will be home free.

I tried to use a bubble leak detector solution that I found at Home Depot, and it works however it is like pouring dish soap on your project. The cleanup is quite large and it has a color to it. I bought two containers of Snoop and I will say it is worth the investment. Much better substance. 

More to follow when I make more progress. I have had the aileron on the bench now for two months staring at me waiting for the trailing edge. That is what caused issues for me the last time, specifically drilling out bad rivets enlarged holes. So this time I will spend time reading about better technique. I also invested at Sun and Fun this year in an old small mushroom set, which was some sort of surplus and it seems that it will do just the trick here without denting the trailing edge.

Tanks are sitting complete, Ailerons again

It does feel good to be done with the tanks for now. In the back of my mind though is the thought that I still am yet to leak test, and I have the potential to have to cut access panels and more proseal. But for now let's put those thoughts to rest :)

Before deciding to move on to the tanks I made the decision to build a new right aileron as I was not happy with the way the trailing edge rivets came out. In my attempt to remove them the holes began to enlarge and I realized this was a losing battle.   The left aileron was 50% complete before putting things away.

So I am back at it, and am starting with the left aileron. I should have a positive future update.

Baffled

Baffle was installed on the right tank last weekend. This is one area where sitting with the plans for some time with a highlighter is wise.

More Fuel Tank Progress

Tanks are complete except for baffles. I highly recommend the preliminary leak test prior to putting on the baffles where you fill the tanks with colored water to see if you have any issues which can be corrected. In my case the problem areas are shown below. The ones at the junction of the three pieces underneath the tank attach bracket are very similar type of joints to the corners of the baffles so lesson learned there. Get an inspection mirror and look underneath the j channel as well as under any joint to make sure you have a fay seal with NO small pinholes. The nut shown below has proseal around it but there is a very small hole where the sealant failed to settle. Liquid will find its way out.

Once that is complete I will start the baffle work. I will not spare the proseal because the last thing I want/need is to have to repair the tank once it is closed.