August 13, 2006

Today I wanted to get these wing tips wrapped up. That involved getting the foam strips laid in, and a lay up of glass on top.

The first task was to countersink the screw holes so the tip could be mounted. I did this with a countersink cutter in my electric screwdriver. Came out pretty nice. It’s tough to use a countersink cage in a drill because of the small step in the fibreglass to take into account the wing skin.

Once that was done, I mounted the tip and positioned the rib. Here it is, drilled and cleco’d.

I countersunk the holes and epoxied and riveted it in place.

I pop riveted the VOR antenna in a few places to secure it ready for glassing over.

Here’s a foam strip laid in place. I had to slit the strip so it would conform a little easier to the shape of the wing tip. I put the tip back on the plane for this to set up some. It’s quite a nice warm day today, so it shouldn’t take long.

In the meantime, I laid in the upper reinforcement foam for the left wingtip. You can see how I slit it for it to conform to the shape of the tip. It broke in a couple of places, but that doesn’t matter really as it’s the glass that you lay over it that really gives the strength. You can just about see the the other foam strip already glassed over on the opposite face of the wingtip. The Comm 2 antenna is resting against it.

A shot further back. It’s quite important you get back here as this is the area where the wing tip is it’s most flimsiest.

Today, I managed to glass over all but one strip of foam on the right upper wingtip. Most everything else is done. I glassed over the VOR antenna too. I also need to lay in a marker beacon antenna before I can call it done. For that I need some more bit’s and pieces. I put the tips back on the plane to set up overnight. The tips are holding their shape even off the plane now!