AST install / trim servo install

Finally!!! I was able to complete the AST assemblies (again) and get them installed.  They lined up great! A tremendous improvement to what the first ones looked like.  I then installed the push rod and trim servo.  I tested both the fully extended position and the fully retracted position and verified all clearances as per plans. Everything looked great.

Time: 3.25 hrs.

AST assemblies installed

Push Rod installed

Trim servo installed

Trim servo

AST assembly round 2

I picked up the replacement parts for the anti-servo tabs yesterday.  I spent a short time today preparing the parts by deburring and priming.  Hopefully this time everything will come out in alignment.

Time: 1 hr.

Priming of AST parts

AST ready to assemble

Spar Assembly / flaperon hinges

I worked a little back and forth between sections 13 and 14 today.  I was able to complete section 13 - Spar assembly.  That included drilling and tapping of the tie downs.  Also riveting of the attach angles to the spar. As each spar is a little different, close attention was needed to make sure the right holes received the rivets.

The small parts for the flaperon hinges were then deburred and primed.  I riveted the flaperon hinge brackets.  I started riveting the flaperon hinges, but in so doing I bent the Main Squeeze rod. This was in trying to get the rivets nice and flush. I guess I am stronger than I thought. I will have to be careful and not use such force in the future. (Note: The rod and bolt were ordered.)  Now we will have to wait a few days until we can rivet again. I may use the time to prepare wing ribs. We will see.

Time: 4.75 hrs

Spar doubler

Flaperon hinge parts primed.

Tapping tie downs

Riveting attach angles

Riveting attach angles

Riveting attach angles

Flaperon Brackets

Bent rod and stripped bolt of main squeeze

AST assembly warped / Start wing kit

 So after posting to Vansairforce forum about the AST assemblies not lining up, the conclusion is that this is not normal and the AST assemblies must be warped or something wrong with the hinges. I figured I should take care of it. I first tried to figure out the issue exactly. I placed a line across the stabililator and tape the left edge of the left AST assembly even with the stabilator. In this position the middle of the AST assemblies was 3/16 lower and the right end of the right AST assembly was 15/32 lower.  I evaluated the hinges on the stabilator and they are lined up correctly.  The only conclusion left is the AST assemblies must be warped and may have gotten so during the reassembly that we did a few weeks ago to remove the blue plastice inside the assemblies. At this point I think it will be easier to just order new parts for the assemblies and start over.  So we will have to wait a while until I can officially complete this section.

I started on the wing kit by first cutting the attach angle and rib doublers. I deburred them and then primed them. I then started work on the next section by clecoing the spar doubler to the spar channels. I then countersunk the stub spar channel flanges. The use of a drill press made this go fast.

Time: 2.25 hrs

Middle 3/16 low

Right end 15/32 low

Priming of Attach angles and rib doublers

Spar doubler Clecoed to spar channels

Counter sinking of spar channel flanges

Wing kit inventory, AST hinge replacement

I went through an did inventory of all the wing kit.  As far as it looks, we have everything.

With the receiving of a new hinge for the right AST assembly, I tackled the project.  I first removed the old hinge and made sure in drilling the new hinge that the holes would be in a position that would allow it to properly fit in the hinges on the stabilator. After riveting them together I attached it to the stabilator and it fit the nicely in the stabilator  hinge. I bolted the AST assemblies together and noticed the ends to line up with the stabilator.  Is this normal?  I will post to Vanairforce forum.

Time: 3 hrs.

Reattaching hinge on Right AST Assembly

Left AST 1/2 inch high when right is even.

Right AST assembly 1/2 inch low when left assembly even.

Trim servo wiring

Received the crimper for the molex connecters.  I crimped the wire attachments onto the wire and secured the connector on the trim servo bracket.

Time: 0.25 hrs

Trim servo

Wing stand

Since we are waiting for the wing kit to get ready to be picked up I thought I would get ahead a little and create a wing cradle.  While doing that we also created a brace for the tail of the wing cone.  It is a little back heavy so it was wanting to tip up in the front. This helped stabilize it.

Time:  2hrs

Tailcone Brace

Wing Cradle

Pushrod assembly / Empennage Fairings

Small progress with the few remaining items of the empennage. The forward V-stab skin was attached. I then attached the rod bearing and remaining items to complete the pushrod assembly. I am waiting on attaching the servo until I have completed the wiring connections.  I have ordered a crimper that will allow for crimping of the connections for trim servo.  Once that arrives I will complete the servo.

With a little time left I started on the empennage fairings. It began with sanding the edges to within 1/2 inch of the lip.  This was easily accomplished with a wood block and 60 grit sanding paper. The rear portion of the V stab fairing was then shaped with a dremel.  Drilling and attachment will have to wait until next time.

Time: 1 hr

Pitch trim servo / AST hinge issue

Spent a week and a halg with my wife and two oldest children in Guatemala for a "Humanication".  We had a great time, but now it is time to get back on the project.

Spent a small amount of time today attaching the trim servo to the mounting brackets and began assembly of the pushrod.

Before I had left for Guatemala we had ran into an issue with the right AST assembly hinge. The hinge did not seem to align properly. I had submitted an inquiry on Vans airforce forum and received several possibilities. While looking further into the issue myself it seemed that the hinges for both the right and left AST assembly were not mirror images. The hinges were mounted about 1/16 - 1/8 inch differently it seemed.  I just could not understand why.  During investigation I placed the hinge guide template on the hinge and found that when placed on one side the holed lined up with the rivets of the hinge, but when flipped over the holes were off about 1/16 - 1/8 inch.  One would think the template should be symmetrical but for this one it wasn't.  I don't know if it somehow became unsymmetrical as I drill the holes before or if it was that way to began with.  The solution I think will be to order a new hinge, redrill, and replace.  This will hopefully take care of the issue. My wing kit should be ready next week to pick up so I may just pick up the hinge then also.

Time: 1 hr.

Pitch Trim Servo

Pitch trim servo and push rod

Hinge hole guide placed one one side

Hinge hole guide flipped over showing misalignment