Static test at full throttle:

Seems I've dedicated all of my 'motor floater' time to non-blog activities. I have so many pictures and videos of the process, so this is quite out of order, time-sequence-wise:

Lower, center wing: perimeter/finish tapes applied, primer next...

Fast forward after three cross-coats of primer and four coats of latex:

Some progress has been made...

 I really should go back and update this blog, shouldn't I? 

Wing: Ribs, Leading and Trailing Edges

The weather has driven the project indoors, so the work tables have been placed and leveled, and work continues on the lower center wing section.

Wide-angle view of the shop area.

The ribs are temporarily removed while the trailing edge framework is fabricated.

After the ribs are bound in place with epoxy resin and fiberglass, the leading edge foam panels are fitted and epoxied. Some cutouts are made to accommodate strut channels.

Some epoxy and micro-balloon filler on the underside helps reinforce the panels.

A Surform plane makes quick work of the foam, matching the contour of the ribs.

Next, the trailing edge foam is fitted and epoxied into place.

The wing section is flipped over now, elevated, and the epoxy resin and fiberglass strips applied.

Vinyl spackling is applied to fill in voids then sanded with an open mesh cloth - typically used by drywallers for smoothing dried joint compound. The center third is coated with epoxy resin. The resin should resist any potential fuel spill, since the tank will be sitting on the top of the wing (near the cross bracing seen above). If a solvent-based wing covering adhesive is to be used, the entire length would be coated. In this case, water-based Stewart Systems is anticipated, so Zinsser 1-2-3 was used on the outboard sections.

Building the Wing (Well, 1 of 6 Anyway)

Finally, time to build what most people would associate with an airplane (technically a 'vehicle' since this is an FAR Part 103 ultralight) - a wing. Only one new skill is anticipated: assembly of stainless steel cable, thimbles and Nicopress sleeves.

Wing assembly well under way.

Use of vinyl tape to assure a closer fit between main spar and inner reinforcement tubes. In this case, two thicknesses.

First step: spread thimble open to accept the thimble bushing.

Place the bushing and slide the tang over the thimble and into the bushing slot...

Restore the thimble to its original shape.

Nicopress sleeves and press.

Squaring up the frame by measuring diagonally across four long temporary bolts at the corners. Fixed in place with a wood scrap and clamps

Other side (out of picture) pre-crimped, getting ready to crimp this side.

Rib bending table with full-sized template as a guide

The end ribs are riveted and braced. The inner six ribs will be 'floating' - secured with epoxy/fiberglass bands.

Stanley saw horses were on hand and worked well enough.

Finishing some ribs. Used ViseGrips, jaws partially open about 1/4", to work the ends closed. Touched up on a piece of steel rail (train track) using a bronze hammer. Clear shipping tape keeping the template usable.

Ribs in place.

Rib ends temporarily taped in place with vinyl tape.

Another view. This was the last good weather day for the season. Shop moved back into the basement until spring. Sigh...

Elevator Build

Bending the trailing edge tubes.

 

Test fitting the Elevator Control Horn Assembly

Fitting the ribs for gluing.

Setting up two leveled tables for rib fitting.

Wire used to keep inner reinforcing tube from shifting out of place.

Kitchen microplane used on foam to achieve desired shape.

Leveling out temporary ceiling hangers.

Epoxy layup of fiberglass. Painters tape helps keep ends in place during curing.

The day was a bit cooler than optimal for epoxy cure. Sunshine helped out.