Wing - Fuel Tank Cover

Ok, so I decided to install the right wing fuel tank cover today. A simple task. So simple the manual dedicates two sentences to it...

14. Top Fuel Tank Cover
AAW-A015

Match Drill all mounting holes in perimeter. After the tank is installed match the filler hole to your tank location.

So, I pulled the cover out, put it in place, measured to make sure it was square. I then clamped it in place on the inboard end and taped it on the outboard side so it wouldn't move. I used my hole finder for the #30 drill bit and drilled out a couple of holes. Because the rivnuts were already in place, I needed to drill the holes I just drilled out to 9/64 for the screw. Once I got several holes done, I placed screws in them to help hold the panel in place

I continued on until I finished both the front and back sides when I noticed that only three sides of the panel had slightly bent edges. The edge that was flat was facing outboard. I thought this was strange but the manual didn't mention anything about it. So, I texted Jak at the factory with a picture and asked which way it should be facing. Of course, I had it wrong, the panel was backwards. Really? Once again, the crappy manual reared it ugly head.

I pulled the panel and took it over to my brake and put a bend in the end where there was none and took the bend out of the side where there shouldn't be one. Fixed. Just another PITA created by the lack of a sentence: Caution: bends face down and the flat side faces the fuselage. Simple.

Wings - Slats

Started working on the slats for the right wing. Pulled all the hardware and began first by installing the arms in the wing. The slats were built by the factory, mounted and the arms were adjusted. So, I just had to reinstall them and verify I had all the parts. The arms were engraved at the factory to ensure proper placement on the wing.

First, I installed the rubber arm bumper on the arm bracket. Next, I had to install bearings on each bolt which I pressed on. Once those were all in place I could install the arms into the wing. There are two bearings per arm.

Each slat must be installed in a specific spot. Once I figured the order I started trying to fit each slat onto the arms. There is a trick to installing them which took some time for me to figure out. The manual is moot on this. Anyway, the slat needs to be rotated onto the arm while the arm is almost completely retracted into the wing. I found that it is easier to do this with the wing inverted on the rotisserie.

 

After much trial and error, I finally was able to get the slats temporarily mounted on the wing and check function. They worked as they should. Once installed, I was able look at where the outboard slat tips will be mounted. They will be riveted on to cap one end of the slat. There are also a couple of rubber bumpers that install in the inside tip of the outboard slat that provides a cushion when the slats bump together. The bumper hits against the slat tip that gets riveted on to the opposing slat.

Header Tanks - Fuel Drains

Since the SuperSTOL comes from the factory with only one header tank and I am going with two, I decided to tackle a small project. There is a small piece of steel welded to the passenger's side of the fuselage for a fuel drain.

I needed to fabricate a similar piece on the pilot's side for my second header tank, and Hysol it into place.

So, I found a scrap piece of .040 aluminum and measured it, cut it, and bent it. I test fit it several times, trimming it to get the angles correct. Once satisfied with the shape and fit, I deburred all the edges, sanded the fuselage where it would attach, and then cleaned all the surfaces.

I mixed up a couple of dabs of Hysol. I placed a metal ruler underneath the fuselage stringers and clamped them in place. this allowed me to set the piece into place on top of the ruler, knowing it would be absolutely flush with the bottom of the fuselage. I dabbed some Hysol into place on each end to tack the piece into place. I allowed the Hysol to set up and then removed the ruler. I mixed more Hysol and filled in the seams ensuring a very good bond. I again let the Hysol set up to working consistency and then smoothed out the fillets using rubbing alcohol. Once cleaned up, I left it to totally cure.

I drilled out the passenger's side and test fit the drain and coupler.

Wings - Spoilers

I pulled all the parts for the six Spoilers for the right/left wings and verified I had everything. I cleaned and deburred the edges of each spoiler. I had to ream all the holes in the spoilers and mounting tabs. I then mounted three spoilers temporarily in the right wing. I will ream the holes in the left wing tomorrow and mount them.

Once I get to covering I'll remove, paint and reinstall them.

Now on to the fuel tanks...

Oratex Covering Sample Kit

I received the Oratex Samples in the mail today. I had Paul Mills of Oratex send me a large sample of each Oratex6000 color, eleven in all. Each sample is approx 2ftx3ft so it's a good size to grasp each color. He also included enough glue to be able to test them out for real. I have an extra rudder and aileron to use as test beds.

So, here are the colors from left to right White, Fokker Red, Corsair Blue, White, Cub Yellow, Olive Drab, Orange (new), Sky Blue, Black (new), Silver, and Light Gray. They are bright colors and look really nice.

Here are the back of the fabrics to show what they look like from behind. A few of the colors have white backs and a couple have black. The rest are modeled as in the last pic of the back side of black.

I have an idea for a paint scheme and was originally planning to use the Polyfiber System and paint the plane. However, the more I think about it the more I like the Oratex and not having to paint. However, I really like my paint scheme and could cover the plane in white Oratex and paint it anyway. There are several advantages to Oratex from my point of view: (YMMV)

1. Lighter weight
2. No painting (if you don't want to) However, you can paint the Oratex, I'm told you just scuff it up with a scotch brite pad and clean it off and shoot paint.
3. It's impervious to UV. This is a biggie to me as I live in Arizona. As a side note, how many traditional fabric airplanes have you seen where the inside of the fabric was not painted and/or primed? Tons. Polyfiber is VERY susceptible to UV light degradation. One must coat the fabric to protect against UV or it will degrade, and fast. In this SuperSTOL, I will have a lot of glass area.
4. Much simpler and quicker to apply.

Ok, so that's it for now. I'll post more once I start working with them...

Tail Wheel Access Cover

I didn't like the tail wheel access cover that was supplied with the kit because it was ill fitting and just a flat plate. I had read about several other kit builders that had a carbon monoxide problem when they started flying and traced it back to the ill fitting access cover. So I made another one that fits a lot better.

I used the original to get me close on the size and shape. I got it cut out and bent up on the brake. Deburred and sanded all the edges. I set the rivnuts for it and mounted it temporarily to check fit and finish. I took it apart to let the LocTite 680 Retaining Compound cure overnight. If I don't remove the screws they'll bond to the rivnuts. It doesn't take long to become a real problem. I found this out on some of the early rivnuts I set for the floorboards. I had to drill a couple out and replace them. :(