3.5 Hours -
The leading edges have proven to be more of a challenge than expected. While Van’s instructions are very good, I’m really starting to realize that a lot of the step by step detail of the empennage instructions is no longer present. I guess they think I can think for myself a little now…
I started by assembling the left leading edge in the cradle. It went together relatively smoothly, with only a couple clecos giving me problems. Once assembled, I moved the leading edge to the spar only to realize that the leading edge skin will interfere with my outboard spar support. To fix this, I had to notch the support angle. It doesn’t look too pretty, but it will do.
The left leading edge assembled in the cradle.
Another view of the left leading edge in the cradle.
With the support notched, I could finally attach the leading edge to the left wing spar. I had no problem clecoing the skin to the spar, but I couldn’t get clecos in many of the rib to spar holes. Either I couldn’t get the cleco through, or there just wasn’t any room to maneuver. Well, it turns out that the holes on two of the inboard ribs don’t align with the holes in the spar and it took me awhile to realize this. Unlike other places in the plans, Van’s decided not to mention it in this case either.
Left leading edge on the wing...for now.
I couldn't figure out why my cleco wouldn't go through...the holes don't match up and the plans don't mention it this time.
I didn’t want to drill the rib holes without having the rib firmly clecoed to the spar, so I decided to remove the leading edge, disassemble it, and cleco the ribs to the spar without the skin. This way, I could firmly cleco all the ribs to the spar and match/final drill them. Hopefully this won’t come back to bite me later.
I had to take the leading edge apart so that I could drill the ribs to the spar.
Here, you can see the new holes that have to be drilled in a couple of the leading edge ribs. It would be nice if the plans mentioned this!
Once the ribs were drilled to the spar, I removed them and reassembled the left leading edge on the workbench. Even though this work took 3.5 hours, it looks like all I did was assemble the left leading edge! If all goes well, I should be able to get the leading edges on the spars (correctly) tomorrow or Monday.
