Aft Wing Rib #9's (2)

2 hours

The #9 aft ribs get a bunch of these reinforcing channels as well as the aileron bell cranks.  I got the channels pretty much done.

Right Main Spar (1)

1 hour

I got a little more work done on the main spar, including drilling the root rib attach angles to the spar and riveting the tip rib angle to the end.  I don't think I can do a whole lot more to this thing until I get my hardware, but it should be here any day now!

This wing attach block is supposed to bolt through those holes on the blue line, but it doesn't quite fit between the spar caps.  I think I will have to trim the corner of the block so I can rotate it into place.

Left Rear Wing Spar (1)

1 hour

I came back this afternoon and knocked out the left rear spar.  It went faster than the first one, but I did make one mistake; I attached the root rib attach angle backwards (I made it the same way as the right spar, but it should be the opposite).

I flipped it around but since I drilled the holes backwards, that puts the angle about 3/32" higher than it's supposed to be on the spar.  I think it'll still work since there's more slop than that when you fit the aft root rib, but I emailed Sonex to make sure.  Worst case I'll have to replace that little angle.

Here is what I messed up.  The root rib attach angle on the left spar (bottom one in this picture) is oriented like the right one, but it was supposed to be flipped around so the flat side faces inboard.

With the attach angle flipped around, the holes still line up, but the part is shifted slightly up on the spar (to the left in this picture).  The top edge of the angle is supposed to line up with the top edge of the plate below it, but it's about 3/32" off now.  I'll have to find out if I can get away with this or not.

Right Rear Wing Spar (1.5)

1.5 hours

Right wing spar just about done; all I need is a couple pieces of hardware and it'll be complete!

This doubler plate didn't quite fit into the radius of the spar channel, so I had to round off the bottom edge a bit to make it fit.

Here's the result of my edge rounding.

Also, the hole in the spar channel wasn't quite as big as the hole in the doubler for whatever reason, so I just filed it until they matched.

Done!

Rear wing spar parts (1)

1 hour

Now that I have most of the parts what were backordered, I can build the rear wing spars.  I started by cleaning up the edges and drilling the pilot holes on these plates so I can fit them to the spars.

Once I get my hardware that I ordered I should be able to complete the main and rear spars!

Backordered parts (1)

1 hour

I got a box today containing most of the parts that were backordered when I got the kit, so I laid everything out to take inventory.

Root rib gussets (0.5)

0.5 hours

I just had a few minutes tonight to sneak into the shops and crank out these last few gussets!  These ones are made of thicker material than the other gussets, so bending the tiny flanges with my little hand seamer was kind of a pain.  But I got em eventually!