Countersunk Left Main Spar, Drilled Left Rear Spar

November 13, 2010

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Well, I managed to motivate myself out into the garage a little this weekend.

I only have a few more steps on the left main spar, and the the left rear spar, before I really need to get my butt in gear with the rib deburring and finally build a wing stand.

Today, I focused on countersinking the screw holes for the tank attachment.

Reading back over my own old post (in which I reference some other builders), I found this table. I’ll copy it here, too.

Countersink Widths for Numbered Screws
Screw Size Width [in]
#6 <0.3125
#8 0.365-0.375

So, I broke out my trusty digital calipers, zeroed them out, and dialed in .312.”

Sorry for the blurry picture.

So, with microstop countersink cage on the front of my drill, I got to work. Here are the smaller countersinks for the #6 inspection plate attach screws on the bottom flange of the left spar.

Pretty countersinks.

Then, I moved up to the 0.370″ countersinks for the larger #8 tank attach holes.

Looking good.

Somewhere in here I flipped the spar over and finished all the countersinking on the upper flange of the left spar.

Sweet.

After the countersinking, I scrounged up the left rear spar and corresponding doubler plates.

Left Rear Spar, reinforcement fork, and doublers.

Per the plans, I grabbed the W-707E and aligned it 50 3/4″ from the outboard edge of the rear spar.

I promise it is right at 50 3/4". I think the paralax make it look off.

W-707F is laterally aligned with the outboard edge of the rear spar channel.

W-707F is clamped and ready to matchdrill.

Here’s W-707E, ready to drill.

After drilling one #30 hole.

All done.

Then, I moved outboard to W-707F.

Before matchdrilling.

All done.

I call this the forest of clecos.

I moved inboard and matchdrilled all of the reinforcement fork holes.

A lot of drilling.

I pulled the doubler plates and reinforcement fork off and set them aside.

I still need to drill out the aileron pushtube bracket hole.

Reinforcement fork pulled off.

Next up, deburr all parts, along with finishing any last minute tasks like dimpling where I can’t reach later, then prep for priming, prime, and rivet the rear spar together.

1.5 hours.

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Hacking the Wig Wag Flasher

November 7, 2010

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It was a great weekend. I didn’t get much airplane stuff done, but I did wake up to this:

 

Awesome.

 

Anyway, the last time I had my B&C flasher hooked up, I thought it was a little fast:

It’s a little fast for me. I wonder if there is a way to slow it down.

A post on the Aeroelectric list last week made me think it would be much easier to fix than I thought.

Since they limit the inrush current it takes longer for the lamps to heat up to maximum brightness.  My fix was to open up the wig-wag flasher and replace the electrolytic capacitor with a larger value, slowing the flash rate down.

After eagerly writing the poster back, he elaborated:

You should only find one capacitor.  It’s a metal can with a plastic case.  Try doubling the capacitance (in microfarads).  It’s not critical.
You can just pry open the bottom to release the tabs and slide the cover off.

Sweet. I went outside and got to work.

 

The cover was surprisingly easy to pry off.

 

 

There's the capacitor, on the upper left.

 

I didn’t think this would be a simple 555 timer circuit, but it is.

 

Let's see, this is a 4.7 µF capacitor. I'll go by a 10µF and 20µF to try out.

 

Oh yeah, almost forgot. A few weeks back I bought an Ideal Crimpmaster tool on eBay for $20. It was the coaxial one, so I had to buy the dies elsewhere. I got them for $20, too, from Stanley.

 

Here are the dies for insulated terminals.

 

 

And the crimping tool.

 

 

My new capacitors.

 

I fired up my (new) soldering gun and heated up the solder on the back of the board enough to pull the old capacitor out.

 

Sweet. That was easier than I thought it would be.

 

 

Here's the 10µF capacitor installed.

 

 

Not great, but not terrible either.

 

So, I put the thing back together and fired it up.

This is the fast version, from my previous post with the 4.7 uF capacitor…


And with the 10 uF capacitor…

I’m thinking I might try the 20µF version, just to see how slow it is. But, I’m calling this a huge success.

Half an hour of wondrous electron-pushing work.

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Napa Valley, Halloween Weekend, Day 4

November 1, 2010

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Alright, today was just a travel day, but there ended up being some nice pictures, so I thought I would share.

(The good news: this is the last day of trip pictures. Next post is back to the airplane!)

Here was an awesome low-level cloud moving in along one of the little bays. We drove right through it over the bridge.

The Golden Gate Bridge.

Golden Gate Bridge.

Awesome.

The pacific ocean.

Golden Gate Bridge.

So. Just over the bridge there was some screeching of tires and an (almost) accident. Once everyone started driving again, we took a look at what we thought was the offending car.

I snapped this picture.

Can you tell what was wrong?

Hilarious.

San Fransisco.

Alcatraz.

More San Francisco.

On the plane, headed back east.

Pretty mountains.

Some awesome formations in the desert.

Same here.

In Dallas, the girlfriend grabbed this sweet picture of the sunset.

And finally, the next morning on the way to the kennel to pick up the puppies, she snapped this picture of the sunrise.

Perfect.

It was an awesome trip.

Now back to work on the airplane, Andrew!

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Napa Valley, Halloween Weekend, Day 3

October 31, 2010

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We woke up Sunday morning (Halloween!) to a gorgeous day. The sun was shining!

After we hugged and kissed the parents goodbye after breakfast, the two of us headed off to hit the last few wineries that were on the suggested lists from some of our wine-industry contacts back in North Carolina.

Since it was so beautiful out, and all the other pictures are of the crummy overcast weather, we got a little picture-happy.

Headed down 29 toward the Carneros region.

Look at that, it's blue sky.

Definitely some pretty landscapes out here.

After a short 15 minute drive from St. Helena to the Carneros region, we pulled into the entrance of Domaine Carneros.

I think I could live here.

The grounds were very well manicured.

The girlfriend made me take a picture of this because the rams looked like something. I can't remember what.

After we got to the main level, we walked around the patio area. I can’t believe how picturesque everything is.

This is looking...sorta...northward.

I'nm loving this blue sky.

This is looking back out toward the highway.

I know people don't want to look at pictures of landscapes, but it was pretty.

We sat down and were handed this menu by one of the hostesses.

Domain Carneros is owned by the French Champange house Taittinger.

I like their logo, too.

What to drink (at 10am)? Life is so hard.

I loved these columns.

They just seemed so old-world to me.

Next, a true Frenchwoman came out and asked us about our “tasting preferences.” Her name was Nicole. She had the most beautiful French accent, which perfectly rounded out the whole sparkling wine tasting experience.

Here she is with our two tastings.

Mmm. Sparkling wine and Pinot Noir.

And now, a never-before scene posted on the build site….

A romantic moment!!!

And then, of course, I reverted back to landscapes.

Yup. I could live here.

After finishing our tasting and heading inside to the cashier (to buy a few bottles), we headed off to the industrial district of Napa (one of the actual cities in Napa Valley).

This bride is over the Napa River. Instead of taking a picture of the river, I am still focussed on the mountains.

Hey look! It’s Falcor.

This place was awesome. These guys were very generous with their pours, they had football on the big screen, and there were two dogs playing in the foyer. Way to steal our hearts, Falcor.

Here is our host. From what I can remember, he runs the show here with his girlfriend.

Private tasting room.

Here's the foyer with his girlfriend, a couple custom crushers (they bring their grapes to Falcor to make their own wine.)

They basically made us try everything they had. Here are the nine (what I’ll call “standard”) wines. After these nine, he busted out the zin port.

One of each, please!

The two dogs.

They were so cute.

Umm. I think this is the “Welcome to Napa” (the city) sign. Later on, I think I grabbed a picture of the “Welcome to Napa” (the valley) sign. That’s the famous one.

Headed back into the city from the industrial district.

Alright, Andrew. Stop taking picture of landscapes.

Seriously. Stop.

There it is! You'll have to click on the picture to read it.

The guys at Falcor highly recommended the Rutherford Grill.

Mmm.

Nice interior.

This would be an awesome casual dinner spot.

They offered us a seat outside (of course! the sun is out!).

It was still a little brisk, though, so they put us right in front of the fireplace.

Whoa. I think this was the best food of the whole trip.

This is the catch of the day with "very" wild rice.

I think this was a chicken sandwich with garlic mashed potatoes.

So all weekend we kept seeing the Napa Valley Wine Train. I guess it starts in San Francisco and stops at all of the little downs up and down the valley. I really wanted a picture of it, so I was going to get up and go frame it really well.

Then I saw this awesome chick standing on the wall doing some weird interpretive dance thing as a pose in front of the train.

Yup. I’ll take a picture of that too.

You just made the internet, honey.

Oh. I almost forgot. I wanted to take some picture of the beautiful landscape in case you hadn’t seen any yet.

[sigh]

I don't know what got into me.

Now we are on our way to Plumpjack. Cool place, but our mouths were ruined from Lunch (tasting wise…lunch was awesome, but way flavorful).

Driveway to Plumpjack.

Patio at Plumpjack.

More Plumpjack.

They had really cool grounds.

I think the girlfriend was in the bathroom, and I was bored.

Okay, now even I am getting sick of these.

We didn’t really have a good experience there. The guys were busy, and basically didn’t tell us anything about the wines.

Finally, our last winery of the trip…Silver Oak.

Nice approach.

Looks like some new vines.

Even at the last place, I had to get the view.

Their building was really cool.

I loved the stonework.

And this awesome infinity pool block.

Inside, we had a couple tastings of magnificant wine, but all the bottles for sale were upwards of $70 and $100. It was good wine, but we found bottles that knocked our socks off elsewhere for $30 and $40.

They did have a cool wine cellar area.

That's a big cork! (Said like "that's a big a meatball!")

I bet I could fit this wine cellar in my house.

I'd just have to rid of a few bedrooms.

Here’s the tasting bar.

Nice, but merh on the prices.

I just deleted a whole bunch of pictures of me in the hot tub. You guys didn’t want to see that.

That night, we did Go Fish for dinner. Great food. Crummy martini (I said "DIRTY!")

Tomorrow, we head home, but I still got some cool pictures of the drive back (not as many landscapes, I promise.)

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Napa Valley, Halloween Weekend, Day 2

October 30, 2010

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Well, after a good night’s sleep, we woke up, had a wonderful breakfast with the parents, and got ready for the day.

We had arranged with Tom D. from Vino Van Tours to take us around Napa (great recommendation from our cousins who had used him before).

It just so happened that one of my buddies was in CA on business, so he drove up and joined us for the day.

After meeting Tom, we headed out for Trefethen.

Trefethen.

We were going to do some sort of private tasting, but they couldn’t promise Tom anything specific because they were setting up for their big Halloween party.

Why does everyone love their big pumpkins out here?

Inside, they had the placed decorated from head to toe.

This is with flash. It was pretty dark and spooky in there.

I can't tell if he is saying "Don't touch my wine!" or "My precious!"

Here is one of the tasting guides. Creepy.

They had a nice tasting for $15. The dry riesling was especially nice, but we ended up buying their 2000 Library Chardonnay.

This lady walked by us, and we thought it was a real dog. She had her left hand in him operating the head, and it scared the crap out of us.

Awesome.

Very well decorated.

This is their barrel room with a flash.

Without flash. That ghost is pretty cool.

After heading out, my buddy was able to snap this picture of the family.

Who's that goofy guy on the left? (Looks like he's been drinking wine!)

Next up, Bell.

We had a few people reccommend Bell, and it was by far the best tasting experience we had.

The outside of Bell.

First thing, Tom walked us by one of their presses, which was actually pressing! (I’d never seen one in action before, just the sparkling clean ones just before or long after harvest.)

It took ALL of my willpower not to go lick the side of the press. Mmm. Wine...

Back in the tasting room. Sandra Bell (Owner/Cofounder) took care of us and poured us our first glass. We got to talk a little about a mutual friend. Very hospitable.

A bad picture of some of the shelves in the tasting room.

I was too busy enjoying myself to take more pictures, but they walked us through 5 wines, and had a cheese pairing for each one. They spent about an hour with us just talking about wine, answering some questions, and talking a little more about the history of the valley.

Nice private tasting room.

Then, I got a little camera-happy. I’m only going to show you one of the (maybe) ten picture I took of the tanks.

Fermentation tanks.

Next, Tom took us to a place called Cornerstone, which was a tasting room only in the middle of Yountville.

Nice little shopping center area.

Here’s the inside.

That's top, on the right (underneath the light).

I liked their logo.

We went a little out of order. First, the sauvignon blanc, then the ’05 Howell Mtn cab, then the ’05 Napa cab, then back to the ’04 Howell Mtn cab.

Nice menu.

Here’s the Sauvignon Blanc. They had bread (needed at this point) and olive oil. Very elegant setup.

Mmm. Bread.

Then, things got a little out of control. Wine everywhere.

We were having a good time.

Proof that we were really in Yountville.

Then, we insisted we sit down for lunch, we were all a little….hungry. Yeah, that’s it.

Doesn't that look delicious? (It was.)

Back on the road, here is Tom telling us the famous Mondavi brothers story.

This minivan had a mind of its own, though. I couldn't get the seat to unlatch, so Tom always had to walk around and get it for me. Must be "all in the wrist."

Here we are (after lunch) driving to Rubicon.

Rubicon is Francis Ford Coppola's place in Napa.

Nice entrance.

A few pictures of the scenery, for your viewing pleasure.

So pretty, even when it is overcast.

Pretty house.

Pretty road.

Here's the front of the winery.

The fountain and some vines.

More pretty.

A nice picture of the fountain.

I could tell you about the rich history of the building, but I won’t.

Nice stonework, though.

Looking toward the tasting area.

Guess who is camera happy.

Enough pictures, Andrew.

Another picture of the tasting bar?

Oh, there was a little room for Coppola’s stuff. I didn’t know that Nicolas Cage was his nephew. Huh.

Merh. I have one of those at home too. (no I don't).

This is an appropriately lit picture. Tom was telling us about his supernatural experience at this winery.

After Rubicon (the wines were good, but I think lunch ruined our palates, and we didn’t buy anything), we headed up to Howell mountain to Ladera. Awesome place.

Pretty mountainous winery.

A picnic would have been nice.

Nicely landscaped grounds.

Here's my buddy, desperately searching for his next Cab fix. Just kidding. (I liked Ladera, because they didn't feel like they had to have a gigantic pumpkin.)

More awesome stonework.

I guess this was a pretty driveway. Why did I take this picture?

I loved all of the winery doors.

Back at the hotel, we assessed the damage. 12 bottles. Not bad.

Mmm. It's going to be a good couple of weeks (or months) at home when we get back.

For dinner, we went to Farmstead. Very organic place (although they didn’t really sell that part well.)

This was after dinner (and wine), so sorry about the lighting.

Hey look! Andrew's getting artsy with his camera-work.

Day 3, coming soon.

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Napa Valley, Halloween Weekend, Day 1

October 29, 2010

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I know there hasn’t been very much airplane work in awhile. But I can explain.

The girlfriend and I have been dreaming (and saving) for a wine trip for awhile. For about 9 months, we’ve been planning a trip to Napa Valley, CA.

It was awesome.

This post is going to be pretty long because of all the pictures. Bear with me.

First and foremost, we showed up to the rental car counter in San Fransisco, and among a lot of the choices was a Nissan Cube. We decided that the Cube sounded like a perfect (pronounced “hilarious”) vehicle for our wine adventures, so we got it.

 

See? Hilarious!

 

We stayed at the Harvest Inn, located in St. Helena, CA. It was wonderful. (Quiet, two heated pools and hot-tubs, complimentary wine and cheese tastings from local vineyards between 5:30 and 6:30 on weekends, and a small bar that was open until 11 every night. (An oatmeal stout is a perfect nightcap after a long day of tasting and dining.)

 

Cute little bar.

 

Okay, let’s get started on Day 1.

My parents happened to be in Napa the same weekend (not so much of a coincidence) and we decided (with some help from friends, other suggestions) that we were going to follow the “once you’ve been on one wine tour, you’ve been on them all” philosophy.

Side note: I love wine tours. Even though all destemmers, presses, fermentation tanks, barrels, bottles, and tasting rooms look a lot a like, I’ll go on as many as you’ll let me.

We decided our one wine tour should be Opus One. They only do tours (by appointment only) at 10am on Friday and Saturday.

Let me just say, the next hour and a half of my life was a life-changing one. Religious experience.

 

Here's the approach to Opus One.

 

 

This is around the side of the building.

 

 

These are some (very well manicured) grape vines on Opus One's property. Beautiful.

 

 

Mom and dad, walking up to the entrance.

 

They had some beautiful olive trees in the open area inside the courtyard.

 

Olives!

 

 

More olives!

 

It was gorgeous everywhere.

 

Beautiful architecture.

 

Inside the foyer, you can see they are getting ready for Halloween.

We met a nice gentleman from Opus One named Hank. He took us on a wonderful tour.

 

I love the reverse columns in the banister.

 

 

This thing was huge!

 

 

Another great shot of the olive trees.

 

 

An olive with a little drop of water on it.

 

Okay, back to wine.

They have a young frenchwoman as the assistant winemaker. Her job is to basically taste all the different barrels and tanks every day to categorize and record the wines characteristics as it ages. I looked for a job application, but they didn’t need anyone. Bummer.

 

This is a lab job I would take.

 

Then Hank took us into the main winemaking room. I was shocked at the scale (it is small) of the operation.

Without going into too much detail, the reason Opus One is so amazing is the care they put into each step. Some of the larger places use huge machines that really beat up on the grapes, juice, wine, etc. during all of the steps to make many different kinds of wines. Opus one really emphasizes quality over quantity (that’s why they can charge $300 per bottle), and they only make one wine. (Well, sometimes they make two, but I’m not going to explain here…go find out for yourself.)

You can see in this picture their operation is pretty small. From right to left, a destemmer, automatic sorter ($$$), press (roller instead of bladder) and then the must (juice and skin mixture) is sent to the fermentation tanks.

 

Each of the round disks in the floor is a cover to a fermentation tank below.

 

 

GRAPES!

 

Hank explained that they use high density vineyards to stress the vines. Stressed vines give less fruit, but much higher quality fruit.

 

You can see the idea of stressing by the coloration in the vines. The vines on the edges (and along walkways in the middle) have more soil, room to grow, etc, so they are still green. The better-stressed vines are in the middle, competing for resources, and producing better fruit. That's why they are starting to turn yellow/red.

 

 

Hank showing us a destemmer.

 

 

A simple map of their fermentation tanks.

 

We were lucky that they had just emptied some wine from one of the tanks. Now, they are scooping out the rest of the must from the tank.

 

There are a whole bunch of rules about going in there. Apparently every couple years someone dies from suffocation (fermentation=carbon dioxide) because they went in there before they were able to ventilate the tank. Here, you can see the harness and the rope used for safety.

 

They’ll take that extra must, and stick it in another press just to make sure they have all of the (wonderful) wine out.

 

Here's the last press.

 

 

An example with an empty tank.

 

Then, Hank had us descend into what looked like a dungeon.

 

Down the staircase.

 

 

Into a beautiful lower foyer.

 

 

Past some second-year barrel aging rooms.

 

 

And into the tasting room. Whoa.

 

Oh my god. We are going to get to taste some OPUS ONE!

 

Such an elegant presentation.

 

At this point, Hank was just teasing us. He asked us to come out into the first-year barrel aging room.

 

They paint the center section of the barrels red so you can't see the drips while they fill and sample the barrels. Nice touch.

 

 

Seriously. This was so cool.

 

Then, Hank handed everyone a glass (it was killing me, he served the ladies first…ugh).

It.

Was.

Heavenly.

 

Tada!

 

So, then the pictures got bad. I was having a love affair with my glass.

 

Girlfriend, Mom, and Hank. (Girlfriend sniffing.)

 

 

She turned around and said "Ooooooooooooh" all giddily.

 

After another 15 minutes of making love to that glass of wine, we made our way back outside.

 

More barrels.

 

Up on the rooftop, we enjoyed some of the (overcast) views.

 

Olive trees, looking west.

 

 

More west.

 

 

Northwest.

 

 

It was so beautiful up here.

 

 

Looking north.

 

 

Girlfriend, mom, and dad.

 

 

Robert Mondavi and Baron Phillipe, founders of Opus One.

 

Finally, we had to go.

 

Looking from Opus One back out toward the entrance.

 

 

Another good shot of the entrance.

 

Next, off to lunch.

 

Taylor's Refresher (now "Gott's?), or maybe it used to be Gott's. I don't know.

 

It’s this cool little walk-up diner with amazing food and a pretty decent wine list.

 

I had a blue-cheese burger.

 

asdf

 

I nice half-bottle of zin for the family.

 

After lunch, we headed to Rombauer (to try their famous Chardonnay).

I was more impressed with the garden area. I saw a dinosaur in the garden.

 

That's my kind of T-Rex.

 

We walked by a pretty awesome old door, though. This must be for barrel storage.

 

Old door.

 

We like a few of their wines (great Merlot, Cab, and really did like their famous buttery Chardonnay), but the guy who poured our tasting was kind of a jerk. Not modest at all, and I just didn’t feel like buying from them. It was our only weird service experience all weekend.

Next up, Sterling (for the tram ride and views).

 

All of these places have really cool driveways.

 

We sprung for the Silver VIP experience.

 

I finally got a picture of my girlfriend's abs on the internet. Ha.

 

So then, we all loaded up onto the tram (gondola?) and headed up.

 

My mom turned to my dad and said, "We forgot the skis."

 

 

Looking up toward Sterling.

 

 

Looking back down after about a 2 minute ride.

 

 

This is Castello Di Amorosa. Kind of cool looking, but I've heard it's hokey and has bad wine.

 

Inside Sterling, they hand you a glass of wine, and send you on a self-guided tour. (Every 50 yards or so they fill you back up with something new.)

 

Some fermentation tanks.

 

 

Some old, but huge, barrels. I can't remember if these were used for fermentation or just large-scale barrel aging.

 

 

Lots o barrels.

 

At the end of the self-guided tour, you end up on a pretty balcony looking south over much of Napa Valley.

 

Looking south over the valley.

 

 

Nice views.

 

 

I liked this bell.

 

Back inside, we headed to the tasting room, and were seated for a nice tasting.

 

They were all pretty good, but none of us bought any wine. I think lunch killed our palates.

 

Next, off to Clos Pegase. This place was suggested for the art and archtecture, but not necessarily the wine.

 

Cool place.

 

 

The light was actually pretty good for some of these pictures.

 

 

I don't know if one of these "L"s fell down or that is how it is supposed to be.

 

 

Looking down one of the vineyard rows.

 

 

Hey, look! Art!

 

 

This is looking toward the tasting room/building.

 

 

I heard there is a giant hand underground. I believe it.

 

 

Very pretty building.

 

After a few more pictures, we decided to actually go tasting, and I ran over to these vines (which still had fruit on them) and picked a grape.

Wine grapes taste very different (kind of bitter) from regular store grapes. I was waxing poetic about how awesome it was when a gentlemen from the winery walked past. I looked down sheepishly, trying to avoid his eyes, and everyone started toward the tasting room.

As we all walked toward the door, he leaned over and said, “don’t worry, everyone does it.”

Darn. I thought I got away with it. Puts a whole new meaning to “caught red-handed.”

 

I can't get over how beautiful the views are. Here's the crime scene.

 

 

Alright Andrew, you are getting a little camera-happy.

 

 

Seriously, Andrew. Put the camera down.

 

 

”]Hey, more art!

 

 

But more importantly, WINE!

 

I took a picture of the tasting menu mostly because this is the only place we bought wine on Friday. Based on the recommendation, we were going to like the architecture (which we did) more than the wine. We loved the Syrah, and bought two bottles.

Take that, overly-commercialized Sterling.

 

All excellent, we liked the Syrah and Origami the best.

 

 

They have an artist onsite designing labels. Pretty awesome.

 

 

Random trunk.

 

 

Barrels and art.

 

This is my favorite picture from the whole trip.

 

I giggled for about 5 minutes at this. I'm not joking. My mom had to drag me into the next room so I stopped laughing.

 

 

Wholy art.

 

 

This guy looks like he is reaching for the vineyards.

 

 

I should really put the camera away.

 

 

Columns.

After wine tasting, the girlfriend and I thought it would be a good idea to hop in the hot tub.

She grabbed the camera away from me, so lucky you, here’s a picture of me running from the camera in my bathrobe.

Yup, this is in public.

After much running, I finally slowed down enough for her to catch up and snap a posed shot.

Dinner at Brix that night was fantastic. Highly recommended. I’ll post Saturday’s pictures soon.

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Tank Attach Nutplates, Left Upper Spar Flange

October 23, 2010

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After getting a ton of housework done, I managed a quick half hour in the garage to finish up the nutplates on the left spar.

I took some pictures, but they are just like the ones from the previous post, so I’ll be short with the descriptions.

 

Countersinking.

 

I found it a little quicker (and less tiring on the drilling arm) to do 4 at a time. I’d countersink four sets of holes for the nutplate attach rivets, then cleco one side of a K1100-08 nutplate in, squeeze the rivet, and then take out the cleco and rivet the other side in. Then move on to the next four.

I’m sure it didn’t actually save me any time, but for some reason it seemed quicker.

 

Just squeezed the first four rivets on this flange.

 

 

Nice looking shop heads, if I do say so myself.

 

 

Another angle, I guess?

 

 

Remove the cleco.

 

 

Put in the other rivet (man, I was really camera happy today...)

 

Everything was going great until the VERY LAST RIVET.

[sigh]

 

For some reason I lifted up the squeezer as I set the rivet.

 

 

Another angle (except it's the same angle). Sorry.

 

After successfully drilling the rivet out. I was left with a crooked nutplate. Hmm.

 

Problem solving time!

 

I didn’t have a clamp small enough to hold the nutplate in place while I reset the rivet, so I grabbed one of the #8 screws (forgot the part number, sorry), and screwed it in gently.

 

Wuhoo! I think this is going to work!

 

asdf

 

(Screwed in gently) because I hadn't countersunk yet. This worked great.

 

 

See, I told you it worked great.

 

Last, but not least, I squeezed the AN426AD3-6 rivets for the K1000-4 nutplates near the spar root.

 

Flush side...

 

 

Nutplate side.

 

64 Rivets, ONE drilled out  in 0.5 hours.

Oh, and then I went for a run with the pups. (And by run, I mean rollerblade.)

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Tank Attach Nutplates, Left Lower Spar Flange

October 21, 2010

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With the girlfriend gone for the night, I managed to clean up all of the electrical stuff I had out messing around with my wig-wag experiment, and pulled the left spar out of the box. Here it is, in all of it’s golden glory.

Golden Glory!

First step is to countersink the tank (and access plate) nutplate attach holes. First, you have to run a #40 drill through the holes or else the countersink pilot won’t even fit in the hole. Here’s one of my first countersinks on the left spar.

I went back and cleaned this one up after testing with a AN426AD3-11 rivet (-11 because it's easier to get back out while testing countersinks...it's so long you can just push it back out from the back.)

These countersinks are a little better. (The one on the right is a tad deep, but should be okay because these are just nutplate attach holes.)

I left the door to the house open so the pups could come out to visit.

Hey guys (Jack and Ginger).

Hey Andrew, how about one of those artsy shots down the spar after countersinking the nutplate attach holes?

Sure, here you go.

Then, I pulled the K1100-08 nutplates out for the tank attach holes and the K1000-06 nutplates out for the access plate holes, then clecoed one side in, and put the required rivet (AN426AD3-4) in the holes.

Where’s my squeezer?

It's right there on the table, dummy.

Then I squeezed some rivets and removed the clecos.

Squeezed (repeated 41 more times.)

Other side done. (Repeated 41 more times.)

Under the hood, things look good. I still like this new Cleveland main squeeze much better than my economy squeezer.

Pretty shop heads.

Down the row.

I then laid the spar down and saw this guy.

Yikes.

Whoa. Scary.

After a little internet research, I think I’ve figured out he (actually she due to her size) is a red-back.  I’m going to keep looking though. I don’t want it to be a red-back.

1.0 hour. 84 rivets.

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FINISHED DEVINYLING WING SKINS!

October 18, 2010


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WUHUOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOO!

(Not that I don’t like devinyling…)

No really, it’s kind of mindless, easy time-passing.

The real reason this is a win is that it is really the last thing (except for all of the leading edge, aileron, and flap skins) I can devinyl in the airplane room before needing to buckle down, finish up the floors, and really get started on the wings.

 

I think this is the right upper outboard skin, skeleton side.

 

 

And the other side.

 

Once I really get going on the other side, I need to catch the left main spar up to where the right is, build the left rear spar, and then do the rib prep trick. Then, I’ll build a wing stand and start the fun parts (Ha! They’re all fun parts!)

0.5 hours.


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Wig Wag FAIL

October 17, 2010


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Okay, so maybe FAIL is a little strong.

Let me back up a few days and explain how I got to FAIL.

Last week sometime (can’t remember when, it was a rough week at work), I ordered some things from B&C to make the wig-wag circuit I’ve been dreaming up.

Anyway, a small box with all my goodies appeared on Thursday, so of course I stayed up late trying to put my circuit together.

All I have as far as electrical tools is one of those $5 combination crimper/stripper tools that really sucks. After an hour of wiring, my hands were killing me, frustration levels were really high, and I made the decision that I needed both an automatic stripper (I hope that doesn’t set off the google search alarms) and a professional crimper. More on those later.

Anyway, that night, I ended up with this:

 

Look ma! I'm wiring!

 

+14V will come in to the left, and the lights will be connected to the center terminals of the 2-3 switch in the picture. the fast-on connector at the top of the picture will eventually be connected to a timer circuit that will close the relay (top left) after 30 seconds.

It was too late to start hooking stuff up. Now. Back to the tools. I ran off to Lowe’s (after considering buying these things on eBay…no, they need to be sharp, and Lowe’s has the name brand one I want), and bought the STRIPMASTER.

 

Seriously. That's the name you come up with?

 

 

A closeup of the important bits.

 

And since I had never seen one work before, I grabbed this short video.

Pretty slick, huh? This is instead of about 60 seconds worth of stupid tool-knife-stupid tool-hurt hand-knife again-stupid tool just to strip one end of one wire.

Okay, let’s find some lights and start pushing electrons around!

 

These will do. 12V, 50W. (Enough for a spare for this little experiment.)

 

 

I fabricated 4 little tube crimps to connect 16AWG tefzel wire to the lights.

 

Oh, and the wood is so you don’t start melting the nice carpet you’ve purchased for the workbench top. Ask me how I knew to do this.

 

Wuhoo! It's alive!

 

Okay, let’s hook up my circuit.

This is LDG ON and WIGWAG OFF.

 

Sweet. Electrons are still flowing.

 

But. This is where bad stuff starting happening.

I threw the WIGWAG switch to ON and then used the simulated timer circuit to close the relay. Nothing happened (lights stayed on).

After a little more investigation, I figured out that both the normally open (NO) and normally closed (NC) contacts were getting +14V all the time. Tha’ts not good. (I knew I needed some diodes or something. I’ll investigate further seperately.)

During the investigation, I wanted to make sure that everything works as advertised.

I wired up the flasher from B&C. I don’t think it’s working correctly. What do you think?

It’s making a weird buzzing noise, and the first light comes on, then the second one starts to come on, but it doesn’t really finish a singe cycle. I’ll have to email the aeroelectric list about it and see what they say.

Since I didn’t get that huge satisfaction of a completely working circuit, I grabbed an automotive flasher I had on the shelf.

It’s the wrong flash pattern, and it won’t work with alternating lights, but it’s still cool.

Finally, I bypassed the B&C flasher and checked the relay operation.

First, I turn on the lights. Then, I turn on the wigwag, and the lights stay constant. Third, I’ll close the relay so current flows through the flasher (although since it’s not hooked up, the lights should turn on.) Let’s see what happens.

Wuhoo, my one electrical engineering class in college has paid off!

This was about an hour’s worth of work, and since it’s ultimately for the build, I’m going to count it as R&D time.

1.0 hours.

Oh, and the next day, I hooked just the wig wag portion up to my car battery, and it worked (I wonder what’s going on with my power supply…).

It’s a little fast for me. I wonder if there is a way to slow it down.


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