This morning I tested the right fuel tank for leaks again and found another leak that I missed a couple of days ago. So I mixed up another batch of the quick cure tank sealant (AC-240) and made a spot repair. It was near the inboard leading edge. I decided to try to accelerate the curing by placing a space heater next to the sealant. According to the tech sheet you can force cure up to 150 degrees.
Today I cut the hole in the bottom skin for the Gretz pitot mast and fabricated the doubler plates and reinforcement angle. This all had to be self engineered so the process was slow moving, but everything came out good. I ordered some White powder coating to finish the pitot mast. It should be here Tuesday. I also drilled another hole in the first few wing ribs and relocated the magnometer wiring to the new hole.
This afternoon I fabricated the mount for the Garmin Magnometer. I adapted the ADAHRS mount the Van’s designed for Dynon. I also dimpled the J-Stiffeners, aileron gap fairings, flap gap fairs and bottom skins. Tomorrow I’m gonna try to get everything primed and ready to rivet. I’m waiting on a few odds and ends from various suppliers before I’m ready to rivet on the bottom skins. I expect to get them riveted on this week though
Tonight I spent a bunch of time trying to figure out how I could enlarge some of the systems holes that I drilled earlier. Based on Van’s wiring and pitot routing, the plans are optimized for using the Dynon ADHRS mounted in the wing. The pitot and AOA lines terminate a few bays shy of the root. So Van’s put’s wire in those holes once you get inboard of that location.
Today I leak tested the tanks. I pressurized the tanks to about 1 psi and spray soapy water all over them. The left tank came up leak free! The right tank however showed a couple of leaks on the outside corners. So I mixed up some fast cure sealant and resealed the leaky areas. Hopefully I’ll be able to retest tomorrow or Monday. After I resealed the right tank I mounted the left tank to the wing assembly.
Tonight I fabricated the landing light lens for the right wing. I also installed the Aeroled landing light and began wiring the right wing
Landing light and lens installed Landing light lens fabricated and ready to go in Autopilot servo, aileron trim servo and light wires installed
Tonight I fabricated the landing light lens for the left wing. I had worked on it a couple of weeks ago but I cracked it. The replacement got delivered last week. Take two and all went well. I also installed the Aeroled landing light and began wiring the left wing
Landing light with lens installed Had to make spacers for the landing light bracket. Decided to use the lathe to make them The spacers Starting to install the wires
Today I finished riveting and sealing both fuel tanks. I am glad that’s over and done with. Building the fuel tanks is a super unpleasant task. This is the second time I’ve built fuel tanks, and each time I’ve said never again! Glad it’s done. Now I need to wait till the weekend and let the sealant cure before leak testing them.
Fuel level sensor (float) installed Rear baffles and Z-Brackets installed.
Today I riveted in the J-Stiffener and tank attach bracket into the right tank. Then I installed vent line and inboard rib in both tanks. Then it Wendy came down and helped me apply sealant to all the rivet heads in the inboard and outboard rib joints. Next up I need to fit the fuel level floats, then I can install the rear baffle and Z-Brackets. I’m starting to see the light at the end of the tunnel on the tanks.
Today Wendy and I finished riveting the ribs into the left and right tanks. We still need to rivet the J-Stiffener and attach bracket on the right tank. Then i’ll install the vent line and fuel float sensor. Then it will be time to close up the tanks.
Wendy laying down tank sealant Left fuel tank with ribs installed