Long EZ N28EZ...The Wings and the Winglets
The next step is cutting the foam, jigging, covering and test fitting the flying surfaces.
The project moved up to the garage. Everything was getting too big for the basement, and we didn't want to be like some builders who have a beautiful, finished airplane, but can't get it out of the cellar! The wing cores have been cut, the same way we hot wire cut the canard, and were assembled in the jig, fixed into one huge, light, styrofoam form.
When I found myself starting to build several different saw horses for different purposes, I came up with this idea that has proved to be a big time and space saver. These two saw horses provide multiple functions. I installed casters on them so that whatever is on them can be easily moved around. That is why the legs are braced in all four directions. They are also different widths, to accomodate the two dimensions at the fore and aft positions of the fuselage. The notches in the top board are cut to fit the upper longerons when the fuselage is upside down on. This prevents the fuselage from accidentally sliding off as it is moved around on these wheeled saw horses.
Once the fuselage is back on it's feet, they can also be used for the wings. The different widths also accomodate the different spans of the inboard and outboard surfaces of the wings, saving floor space when used. Shown in this picture, the hinged boards are in the up position, and lock in place, to provide support at the correct height when installing the wings and inserting the wing attach bolts. Because of their different widths, they easily nest when being stored, so they also take up less space when not in use.
Yes, we did manage to get the fuselage up into the garage! Here it is upside down, with the spar and strakes installed, waiting for a test fit of the wing. The bubble near the top left of the picture is at the juncture of the strake and the fuselage and is the sump blister for the fuel tank.
Some friends from Pittsburgh visited, and their son, Matt, turned out to be a natural manager. Here he is giving orders reagarding something he doesn't like on the winglet. Possibly, the older, small rudder design! With determination like that, I don't interfere...I just let him do his thing.
The ailerons are now finished...literally! The glossy top coat is on and the all important final balancing was done. If too heavy, or out of balance, they would have to be sanded down and refinished. As you can see in this picture, the left one balanced. The right one is the same. Although the level laser line is not perfectly centered beteen the upper and lower surfaces when aimed at the trailing edge, the lower surface does slope away from the line 1/2" at the counterbalance. This is well within the plan's specification. I enhanced the laser line in the image to make it more visible. Note the use of large binder clip handles to hang the ailerons from the hinges! With a little bending, they fit perfectly between every other slot and were just loose enough to allow for absolutely free movement of the ailerons. I bought the binder clips from my local Office Depot Aircraft Supply Center.
I used Poly Fiber's UV smooth Prime on the wing, just as I have the rest of the plane so far. But, the small, 2 ounce bottle of crosslinker had hardened, even though the rest of the primer was fine. I called Poly Fiber for a replacement, which they very happily sent me for no charge! As of yesterday (May 4th, 2009) I have the left wing primed! Now to let it set a week or so to dry out, and then a little finish sanding to prep it for the final coat of paint, and I can apply the urethane. Then I start on the right wing!
June 25th, 2009. Final coat of paint on the left wing, rudder and aileron reinstalled and delivered back to the hangar today. Picked up the filled and sanded right wing, so it won't be long before that's painted as well. I hope!
August 11th, 2009. At last...the final coat of paint on the right wing. Rudder and aileron reinstalled and ready to go back to the hangar. This will be the last update in the wing section...the next time you see these wings, they will be mounted to the finished fuselage!
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