Install port rear spar strut fittings (7V4-4)

Rear upper strut fitting (7V4-4) install at trailing edge of rib #3

Installed rear upper strut fitting (7V4-4) to rear channel at rib #4.  Difficult assembly (pg 7V5).  Requires 12 A5 rivets through 7V4-4 into rear channel, a short L-angle doubler at the rear channel and flaperon mount; and a longer l-angle bent to match the bottom surface of the wing lying along the rear channel.  All require A5 rivets in tight spaces.  Angle drill required.

Complete port rear spar channel installations

Port wing rear spar channels

Finished installation of the rear channel (spar) components.

Started installation of rear channels to create rear spar

Rear channel (spar) installation)

Rear channel (spar) installation

Install the rear channels (prepared with the stb wing build) to create the rear spar.  Used the template from the stb wing construct & same method.

Port wing ribs installation

Port wing ribs behind the nose ribs.

Install (silver) port wing ribs behind the nose ribs.  Assure vertical placement with square.

Install port spar doublers & nose ribs

Port wing nose rib install (silver)

Port wing nose ribs in place

Using the station lines as references, installed the 3 front spar L-angle doublers at stations 480, 1160, & 2760.  Installed all 6 nose ribs in their proper locations assuring vertical placement with square.

Prepare fpr Port wing build

Collected all components for construction of the port wing.  Labeled all parts and scribed all center-lines in preparation.

Fabricated wing wiring harnesses

Wiring harness parts

Grounding busses

Positive & Negative Busses

Added Molex pins to various lengths of cables for later electrical installations.

22 AWG, 2-conductor, shielded (Radio Shack):
(1) 18' tail-light assembly connector to inst. panel
(2) 6' stb wing-tip light connector at wing root to inst. panel
(3) 6' port wing-tip light connector at wing root to inst. panel
(4) 6' AOA vane to port wing root connector
(5) 6' AOA vane port wing connector to inst. panel (indicator)

22 AWG, 3-conductor, shielded:
(1) 4' AOA indicator (inst panel) to buses 

28 AWG, 5-conductor, shielded:
(1) 18' elevator trim servo to inst. panel & pilot stick grip

Fabricate wing storage cradle

Stb Wing in Storage Cradle

Stb Wing in Storage Cradle

Used scrap lubber to fabricate a cradle for upright wing storage.  This will save space and allow the wings to be moved into the storage shed along with the empenage, flaps, and slats.

Fiberglass Wing Root Nose Skin Install

Fiberglass wing root nose skin in place

Fiberglass wing root nose skin in place - wires are for lights & fuel sensor connections

Added epoxy resin with micro-balloons to the nose skin and sanded smooth.  Removed skin from the form and trimmed to fit for installation.

Will try the aluminum sheet nose skin (7V9-3) again on the port wing, but will probably require a port side form for another fiberglass skin.

Wing root leading edge top skin mold (fiberglass)

Wing root nose skin poly-urethane foam mold

Wing root nose skin on mold

Wing root nose skin ready for release from mold

After several attempts to get the nose portion of the aluminum skin to fit the compound curve of the stb wing,  I decided to try mold a fiberglass part.  Made plywood copies of #1 nose rib and root nose rib.  Fastened into position on another piece of plywood.  Used 2-part poly-urethane foam to construct the compound curve of the part & laid-up the skin with 4-oz. fiberglass cloth using West System 105 marine epoxy resin.

This worked well, but I'd have to make the mirror image form for the port wing.  I decided to give the two part aluminum skinning process another try and was successful on the port wing.  I now have one wing root nose in fiberglass (stb) and one in aluminum (port).

Trial fit of wing root top skin leading edge - No Joy

After many hours, could not get the  wing root top skin leading edge to make the compound curve.  Decided to make a male mold to lay-up a fiberglass part.

Trial fit of wing root top skin (single piece - 7V9-3)

Wing Root Top Skin (7V9-3) cut into 2 pieces ... rear

Wing Root Top Skin (7V9-3) cut into 2 pieces ... rear

Spent several hours trying to bend/fit the compound curve of 7V9-3 to conform to the wing root.  Could not make the difficult compound curve around the tapered nose skin.  Decided to try Jon;s method of cutting the piece (7V9-3) into two by cutting along the position of the front spar. 

Rear portion of the top skin fell into place nicely.  drilled and clecoed (silver).