1 hr. riveting in the end rib and routing the wire.

Used two ties to tie the wire bundle up, just to make sure it doesn't easily come lose.

And it's riveted on.  I tried putting the tip in but it wouldn't stay without the missing tip skin in place.  I'll try again tomorrow since it would be good to have that in place by the time I get the piece.  Then I would just need to file down the trailing edge that goes under the skin to get the skin to lay flat.

NEXT TASKS:

1. Wing tip assembly and light installation.
2. Test fit of aileron and flap, with likely adjustment of the aileron to line up the trailing edges.
3. Fill rivets (use filler this time and try the factory recommended method of filling the rivets).
4. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
5. Finish one of the composite tips of the elevator.
6. Fill rivets of elevator.
7. START ON FUSELAGE!

2 hrs. finishing the riveting of the leading edge and starting on the tip assembly.

All done!

The tip is off the jig.  Test fit of the end rib...

And discovered that I have the wrong tip skin...  Turns out I have two lefts...  The instructions underneath show the correct part.  See how it faces the other way (it may look like it's simply upside-down, but it's not)...  The factory will send out the correct part on Monday.  Meanwhile I can still rivet in the end rib, route the wiring through and start the fit of the composite tip.

NEXT TASKS:

1. Wing tip assembly and light installation.
2. Test fit of aileron and flap, with likely adjustment of the aileron to line up the trailing edges.
3. Fill rivets (use filler this time and try the factory recommended method of filling the rivets).
4. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
5. Finish one of the composite tips of the elevator.
6. Fill rivets of elevator.
7. START ON FUSELAGE!

1 hr. riveting the leading edge.  More to go, but getting there.  Hope to finish the riveting tomorrow.  Then I have to remove the tip jig and work on the tip.

Could only do an hour before my back said no more...

NEXT TASKS:

1. Leading edge and fuel tank riveted on. 
2. Wing tip assembly and light installation.
3. Test fit of aileron and flap, with likely adjustment of the aileron to line up the trailing edges.
4. Fill rivets (use filler this time and try the factory recommended method of filling the rivets).
5. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
6. Finish one of the composite tips of the elevator.
7. Fill rivets of elevator.
8. START ON FUSELAGE!

1.5 hrs. finishing the top rivets on the right wing.

Me and my wing. ;-)

NEXT TASKS:

1. Leading edge and fuel tank riveted on. 
2. Wing tip assembly and light installation.
3. Test fit of aileron and flap, with likely adjustment of the aileron to line up the trailing edges.
4. Fill rivets (use filler this time and try the factory recommended method of filling the rivets).
5. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
6. Finish one of the composite tips of the elevator.
7. Fill rivets of elevator.
8. START ON FUSELAGE!

1.5 hrs. riveting...

Lots-o-Rivets!

Getting there!  Plan is to finish the riveting Wednesday.

Know this character?  Made me think of him when I watched the time-lapse video I made. ;-)

NEXT TASKS:

1. Top skins riveted on.
2. Leading edge riveted on. 
3. Fuel tank riveted on.
4. Fill rivets (use filler this time and try the factory recommended method of filling the rivets).
5. Wing tip assembly and light installation.
6. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
7. Finish one of the composite tips of the elevator.
8. Fill rivets of elevator.
9. START ON FUSELAGE!

3 hrs. starting to rivet the top skins of the right wing.

Much of it done.

Time-lapse of some of the time.  My wife and some friends help out.

NEXT TASKS:

1. Top skins riveted on.
2. Leading edge riveted on. 
3. Fuel tank riveted on.
4. Fill rivets (use filler this time and try the factory recommended method of filling the rivets).
5. Wing tip assembly and light installation.
6. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
7. Finish one of the composite tips of the elevator.
8. Fill rivets of elevator.
9. START ON FUSELAGE!

2 hrs. finishing the cleco'ing, reaming out holes that needed it (more than the left wing..) and putting in the rivets.  Tomorrow is the start of the actual riveting.

A sea of cleco's and rivets!

Close up.

NEXT TASKS:

1. Top skins riveted on.
2. Leading edge riveted on. 
3. Fuel tank riveted on.
4. Fill rivets (use filler this time and try the factory recommended method of filling the rivets).
5. Wing tip assembly and light installation.
6. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
7. Finish one of the composite tips of the elevator.
8. Fill rivets of elevator.
9. START ON FUSELAGE!

2 hrs. testing the wiring one last time and cleco'ing the skins on.

Decided to use the wicking Loctite on the tank bolts just for good measure.

All the tip light wiring works.

Landing/Taxi lights wiring works.

Nearly done cleco'ing all of the top skins.

Here's me with my very cool 2014 Oshkosh t-shirt.  ;-)

NEXT TASKS:

1. Top skins riveted on.
2. Leading edge riveted on. 
3. Fuel tank riveted on.
4. Fill rivets (use filler this time and try the factory recommended method of filling the rivets).
5. Wing tip assembly and light installation.
6. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
7. Finish one of the composite tips of the elevator.
8. Fill rivets of elevator.
9. START ON FUSELAGE!

3 hrs. over the last 3 days testing the right tank, re-testing the left (just for the hell of it) and bolting on the right tank.

Held the pressure for more than 24 hours before I disassembled the test fixtures. :-)

Figured I'd connect my newly simplified test fixtures on the left tank just to see if it's still good.  It was easy to connect so I figured why not.

And the right tank is bolted on!  Went much easier than the left.

NEXT TASKS:

1. Final test of the wiring.
2. Top skins riveted on.
3. Leading edge riveted on. 
4. Fuel tank riveted on.
5. Fill rivets (use filler this time).
6. Wing tip assembly and light installation.
7. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
8. Finish one of the composite tips of the elevator.
9. Fill rivets of elevator.
10. START ON FUSELAGE!

.5 hr grinding down the rib to allow a rivet in the top skin.  Waiting until tomorrow to start the re-test of the right tank to allow the sealant to sufficiently set.

A shortened rivet now fits.

NEXT TASKS:

1. Retest right tank on Wednesday.
2. Bolt fuel tank on.
3. Top skins riveted on.
4. Leading edge riveted on. 
5. Fuel tank riveted on.
6. Fill rivets (use filler this time).
7. Wing tip assembly and light installation.
8. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
9. Finish one of the composite tips of the elevator.
10. Fill rivets of elevator.
11. START ON FUSELAGE!

4 hrs. over the last 3 days (my internet was down :-(...) moving the left wing to the shelf and working on the right wing.

Left wing on the shelf and right wing back on the bench!

Right wing ready for completion!

Skins on for a final fit.

One final test of the right tank...

But, found a couple of pinhole leaks (ugh..)...  Here's one around a fitting.  I put the wicking Loctite in there, but I didn't feel that worked great, and I don't really trust it, so I mixed up some sealant and put that on both.  Will re-test in a couple of days.

While it's setting I put it on the wing for a final fit check - A-OK.

Skins back off.

This was a (still unresolved) problem on the left wing.  Part of a rib is too close to the hole above, so a rivet won't fit.  This time I have access, so I'm grinding down that rib so I can get a shortened rivet in there.

The pic is upside down but you can see the grinding down I'm doing.  More to go to fit the rivet.

NEXT TASKS:

1. Retest right tank on Wednesday
2. Bolt fuel tank on.
3. Top skins riveted on.
4. Leading edge riveted on. 
5. Fuel tank riveted on.
6. Fill rivets (use filler this time).
7. Wing tip assembly and light installation.
8. Rivet the one on the left wing's step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
9. Finish one of the composite tips of the elevator.
10. Fill rivets of elevator.
11. START ON FUSELAGE!

1 hr. sanding the 2nd filler coat.

Sanded with progressively finer sandpaper (60, 120, 220).  It feels way better than it looks in the photo.  It's nicely shaped and smooth.  I declare it done!

View from the trailing edge.

NEXT TASKS:

1. Rivet the one on the step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
2. Finish right wing.
   
3. Finally finish one of the composite tips of the elevator.
4. Fill rivets of elevator with Bondo (actually I may switch to using epoxy filler since that takes much longer to harden, so I don't have to keep making small batches of Bondo).
5. START ON FUSELAGE!

1 hr. sanding wing tip filler and applying second round of filler.

Sanding the 1st round of hardened filler.  Wear a mask....  Used some course sandpaper and then finer grain.

Cleaned off with a wet paper towel.

Mixed up another batch of filler (tried to make it thicker this time) and applied it everywhere there seemed to be a dip or larger space that needed filling.

NEXT TASKS:

1. Composite filler sanding, 2nd round.
2. Rivet the one on the step rib that needs special handling (waiting to hear back from the factory on what to do with that hole).
3. Finish right wing.
   
4. Finally finish one of the composite tips of the elevator.
5. Fill rivets of elevator with Bondo.
6. START ON FUSELAGE!

1 hr. applying the epoxy resin filler.

Wear a mask when using this stuff...  One pump from the resin (105) and one pump from the hardener (206).  Mix for a minute then slowly add in filler.... It took a lot more filler than I thought it would to get it to peanut butter consistency, which is what you want for making fillets.  Just keep adding about a tablespoon at a time until you get there.

At this point, never having done this before, I have no idea what I'm doing... First I tried using a Bondo spreader to apply it, but I found it was actually easier to apply with a gloved hand's finger (had latex gloves on both hands).  So, I just spread it in the gap to try and fill it.  Whether I'm doing it right, I have no idea.  We'll find out tomorrow (or Tuesday) when I sand it down.  For all I know, I'll have to add another layer for it to be a good transition and smooth.

Front view.   How will it come out?  We'll see!

NEXT TASKS:

1. Composite filler sanding.
2. Rivet the one on the step rib that needs special handling.  OK, I've been putting this off..
3. Finish right wing.
   
4. Finally finish one of the composite tips of the elevator.
5. Fill rivets of elevator with Bondo.
6. START ON FUSELAGE!

2.5 hrs. getting the aileron right.

De-riveting the entire leading edge of the aileron is the only way to get the warp right (thanks PeterC for the extra push!)...  After I did that I clamped down the right edge.  When you move the left trailing edge up you can see how the holes move.

Moved the left trailing edge up and riveted a middle hole (after drilling and reaming it) on the leading edge.  Rechecked against the wing tip... And I had over-done it by 3 or 4mm....  Ugh.  I removed that rivet, clamped down the left edge as that seemed to be how much I was off now and re-riveted a nearby hole (again, after drilling and reaming it).  Bottom line, it seemed impossible to precisely calculate how much to twist it.  I estimated, that was over, so I estimated again (just using 1 rivet installed).  Trial and Error...

And the result: Absolute perfection!  Not even a millimeter off.  :-}

Another view of the beauty.  Now I just need to do the epoxy filler on the tip and leading edge/fuel tank seam and then it's DONE.  On to the shelf and let's finish off the right wing.  I'm hoping that moves much quicker.

Bonus photo: Found this photo of me in the left seat, around age 14, in 1974 at Spring Valley Airport, now a strip mall..

NEXT TASKS:

1. Composite filler for join between wing tip and skins. Perhaps other seams can use some filler?
2. Rivet the one on the step rib that needs special handling.  OK, I've been putting this off..
3. Finish right wing.
   
4. Finally finish one of the composite tips of the elevator.
5. Fill rivets of elevator with Bondo.
6. START ON FUSELAGE!

3 hrs. screwing in the tip light and working on the left aileron warp...

Got the screws today (thanks BobZ!) and firmly screwed in the light.  Nice!

I've been dreading doing the aileron warping...  I drilled out a bunch of rivets (but not all the way down the leading edge (at least not yet)).  All the way down the top of the left-most rib though since that area needs to move the most.

Pulled up the top skin as much as possible and drilled a new (larger) hole.

Put in a new rivet there and also halfway down the rib (after moving that hole toward the leading edge as possible).  Note the bulge in the skin now along the leading edge due to the shift of the skin.   Measuring on the wing it's been improved about 4mm.  I'm hoping that as I pull it up tightly and rivet more that that will improve...  We'll see tomorrow...

NEXT TASKS:

1. Rivet the one on the step rib that needs special handling.  OK, I've been putting this off..
2. Re-rivet some of the aileron to get it to line up with the flap and wing tip.
3. Composite filler for join between wing tip and skins. Perhaps other seams can use some filler?  Will do this on a day I can open the garage door.
4. Mount light when the screws arrive.
5. Finish right wing.
   
6. Finally finish one of the composite tips of the elevator.
7. Fill rivets of elevator with Bondo.
8. START ON FUSELAGE!

Full article in my local paper is out.

Was featured on my local community TV show:

2 hrs. starting to look at the aileron twist process and installing the other tip light mounting plate.

Got info from Peter on how to twist the aileron to align the trailing edges, but since it's involved I thought it was prudent to check with the factory first before starting to de-rivet lots of rivets.  The right end of the aileron trailing edge needs to come down 13mm.

So, while I await an answer I decided to use the time to work on the other tip.  This tip's styrofoam insert proved to be more difficult to remove.  Had to resort to using a small hack saw to cut through fiberglass that was up against the inside of the styrofoam.

I didn't like the 2nd mounting plate I had made a few days ago so I decided to make another one.  This one came out perfect.

Measure twice....

And the plate is installed!

Nice!  Just waiting for screws to arrive.

NEXT TASKS:

1. Rivet the one on the step rib that needs special handling.  OK, I've been putting this off..
2. Composite filler for join between wing tip and skins. Perhaps other seams can use some filler?  Will do this on a day I can open the garage door.
3. Re-rivet some of the aileron to get it to line up with the flap.
4. Mount light when the screws arrive.
5. Finish right wing.
   
6. Finally finish one of the composite tips of the elevator.
7. Fill rivets of elevator with Bondo.
8. START ON FUSELAGE!