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2-16-2000 Well the parts are here and this thing won't fly in this shape so I had better get started! |
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I would get started if I only knew where to start! Actually the long tubes on the front table are the forward and aft spars and that's where I will begin. |
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You actually start out attaching a lot of these brackets to each of the spars. These will hold compression tubes which connect the main spar and the aft spar together. Most parts come ready to use but sometimes you have to modify the part somewhat. The small bracket in this photo is cut from a larger bracket. |
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This is a example of the plans showing how to modify a part such as the brackets pictured above. |
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3-10-2000 After attaching all the brackets you install the compression tubes. In this picture I have three compression tubes and the wing tip bow at the far end installed. |
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This compression tube also holds the bell-crank system. This will be used to control the Ailerons. If you look directly under the bell-crank you can see the bracket I cut in half as mentioned above. |
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These brackets on the aft spar are stainless steel hinges that the Ailerons and Flaps attach to. The aft spar is a two inch aluminum tube and the front spar is three inches. |
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This is the area where two compression tubes attach to the front spar at the point where the forward wing strut attaches. |
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This photo shows both wings with all brackets and compression tubes attached. I was lucky enough to have enough room to build both wings at the same time. Next step, Ribs, Ribs and more Ribs! |
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4-5-00 There are 22 ribs in the wing of the S7. Each rib has 8 parts held together with 35 Cherry Q Aluminum Pop Rivets. The kit comes with one rib jig to build all the ribs but I built a second so I could build a left hand and right hand rib at the same time. This photo shows the two wooden rib jigs and the rib parts laying out on the work table. |
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This is a closer look at one of the rib jigs. Using the jig keeps all 22 ribs the exact same shape. The ribs are made up of different channels (channels are the two aluminum pieces with the big holes) located in different positions so they will clear the various compression tubes. With enough coffee you can get them all built the correct way! |
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This is one days work building ribs. I mean a LONG day of building ribs. |
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05-07-2000 All the ribs are now built. All of the ribs but four need to have holes drilled for the rivets that I will be using instead of rib stitching to secure the skin to the ribs. To do this I installed all the ribs close together and marked the inside and outside ribs with the correct hole spacing. Next I took a straight edge and marked all the ribs between the inside and outside ribs before center punching and drilling. If you look close you can see the holes on top of each rib. This also had to be done on the bottom of each rib. Would you believe 31 holes on each rib! That's 558 holes!! |
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This in the lower attach point of the forward and aft wing struts. When building the struts I taped one end of each and poured primer paint inside and then drained to get good corrosion protection. Here, I was trying to get the correct clearance between the struts. Notice the aft strut is adjustable. That comes in handy later when setting the washout in each wing. |
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05-06-2000 Outside! Outside! Fresh air, Sun! I think I've been stuck in the shop too long! Its time to install the wing frames and wing struts to set the Washout in each wing. You have to start with the fuselage level so up goes the tail. |
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Goodness I think I can make out a airplane! Sorry for the picture quality but that's too many straight lines for the old digital camera. Here the wing frames and struts are installed. After leveling the root of each wing you move the level out to the strut attach point and add a 1/4" shim between the level and the rear spar. Then you use the adjustable lift strut to re-level. This sets the correct washout. During this time I also drilled the front spar for the 3/8" Clevis Pin and built the Jury Strut Assemblies. Don't tell anyone but I even sat in it and made airplane noises! |
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06-10-00 This is a shot of all the ribs attached to the wing. This is how the project sets at this time. Work has stopped due to some deck building and catching up on my "HoneyDo" list!!!! |
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08-05-2000 "HoneyDo" list, although never complete, is about 80% caught up so it's back to the Kit Plane Building! This is a picture of the fuel tank installation. I now have both tanks and all fuel line fittings installed. Each tank holds 9 gallons. |
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08-19-2000 I have been working on the wings but they are on hold waiting on supplies. To take a break from the wings I went ahead and installed the landing gear and mounted the wheels and tires. |
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Looking more and more like something that will someday have wings. Some guys go ahead and install the seats. I have heard that is not a good idea because the builder will spend too much time setting in it making airplane noises and not building. As tempting as it is I guess I'll wait on the seats! |
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08-27-2000 Well I'm kinda, sorta, back to the wings. I am still on hold waiting on some glue, I mean bonding material. The plans call for you to bond the leading edge of the aluminum wrap to the main spar (notice I didn't say Glue! My wife didn't like the sound of using Glue on the airplane she has agreed to go flying in!). You have to lay down a 3/16" line of bonding material all down the 12 foot main spar(note White Arrows) and clamp the Aluminum tight against the spar till cured. While waiting on supplies I have the leading edge ready for bonding. I have Installed the aluminum sheets above and below the fuel tank and installed the collar around the fuel cap. I have also installed the fuel lines. |
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This is the bracket that holds the strobe lights. It is mounted on the wing tip bow. The plans call for running the strobe wire through the rear spar to the root end of the wing. The wiring will be connected after covering the wings. |
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09-05-2000 I finally got one of the steps I dreaded the most completed. My brother, David, helped me bond the leading edge aluminum to the spar and when we took all the clamps off it stayed where it was supposed to! So good so far! We did the second wing a couple of days later and had a little more trouble with the clamps. I woke up at 2:45 that morning worrying if everything was OK and how I would fix it if things went bad. At 5:30 I went ahead got up and took the clamps off. Everything looked Great! Sure glad this part is over!! |
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09-10-2000 This is the back side of the Wing Wrap. These cross tubes are added between each Rib to help prevent oil-canning. The tube you see going into the front spar is the Static port. The other hole is where the Pitot tube goes in. |
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Well the wings are now complete and ready for covering. I built this cart to hold both wings till it is time to cover them. I also took down the two tables to give me room to work on the fuselage. |
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05-13-01 I have purchased a LRI (Lift Reserve Indicator) for the S7 which will help shorten the takeoff ground roll and climbs will be more efficient, approach speeds slower and landing ground rolls will be shorter. You can see the instrument and the probe that came with the kit. I had to build the mounting bracket you see on the left. |
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This is a picture of the LRI Probe installed in the wing. Keep in mind the probe is mounted in the bottom of the wing and points forward. This picture was taken with the wing turned upside down for easy access. You can check out the LRI at LiftReserve.com . If you order one be sure and tell them I sent you!!! |
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This is the end of the Wing construction phase of the project. Covering will be after everything else is assembled. The Fuselage construction phase will start soon. The project is loads of fun and is my best stress reliever. This web page takes a little time, but I have enjoyed sharing the project with others. Some people tell me I'm just plan crazy! I just grin and tell them I'm "Just Plane Frank"!!
