Monday 3 December 2012

3rd December 2012 - Preparing the wings for the lower skins

Over the last few days I have glued the scarf joint for the other top wing skin and fastened the lower skin to the wingtip of the right wing. Today was spent sanding the scarf joints into the edges of the lower wingtip skins so that the main skins can overlap them. A 12" sanding block was prepared with sandpaper on 4" or so of the surface and then a smooth area over the rest of its length.. This allowed the block to rest on the penultimate rib whilst sanding the wingtip skin to create a flat level with the rest of the ribs. Easy enough to say but a long and laborious process! However, finally both wings were prepared ready for gluing the main skins. Next the full sheets of plywood
for the lower skins were cut down to a width of 42.5" which reaches neatly across the width of the wing. The offcuts will be used for making more sacrificial stapling strips.
A cardboard template was made to fit over the strut attach brackets. Then for each wing in turn the lower skins were positioned and the locations for the cutouts marked. The template was then used to trace the outline and a rotary rasp used in the Dremel to cut to the outline. Following a bit ot trial and error the hole was then made to fit snuggly over the brackets and the wings skins positioned ansd clamped into place. The wings were then turned over and the positions of the ribs and spars marked in pencil - just visible in the picture. These markings will allow the glue to be applied in the right places without too much excess. Like the wingtips, the markings were also then transferred to the outside of the skin to allow correct positioning of the attachment staples into the ribs and spars. Next job to glue one!
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