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...

Rudder Rib and Brace Assembly

 

The aluminum rudder frame has been acetone-cleaned, 80 grit sanded and re-cleaned in preparation for Aeropoxy attachment of ribs and braces. Clear shipping tape was used on the table to prevent sticking, though I've read that two coats of paste wax on the melamine surface will yield the same effect.

Dry fit prior to cleaning

The foam is easily sanded by wrapping sandpaper around a tube to create the groove needed to mate with the rudder torque tube and trailing edge tube.