Wing (November 2003 - May 2007)

I ordered the wing kit on 9/15/03. The website showed 10 weeks lead time, but Van's said it would be 8 weeks. Van's shipped the kit on 11/7/03, one day less than 8 weeks--that's pretty good service.

Total time worked on the Wing: 529 hours

Spars
2003-11-17   3.0   -  Wing kit arrives
2003-11-19   2.5   -  Inventory complete.
2003-11-25   2.0   -  Begin work on the Left Spar.
2003-11-29   3.5   -  Countersink the Left Wing Spar.
2003-11-30   5.5   -  Finish countersinking wing spars
2003-12-02   2.5   -  Fabricate tie-down assemblies
2003-12-03   2.0   -  Working on tie-down.
2003-12-06   5.5   -  Cut holes in spacers, drill tie-down asms.
2003-12-07   2.5   -  Ream out aileron bellcrank bushings
2003-12-12   4.5   -  Assembling the rear spar.
2003-12-13   5.5   -  Assembling the rear spar.
2003-12-14   1.5   -  Assembling the rear spar.
2003-12-17   1.5   -  Assembling the rear spar.
2003-12-20   4.0   -  Primed the rear spar assembly.
2003-12-21   1.0   -  Riveted the rear spar.
2004-01-02   1.0   -  Primed the countersunk holes in the spars
  48    hours

Ribs
2003-12-22   1.0   -  Deburring the wing ribs.
2003-12-23   4.0   -  Deburring the wing ribs
2003-12-24   3.5   -  Deburring the wing ribs.
2003-12-27   5.0   -  Deburring the wing ribs.
2003-12-28   4.5   -  Deburring the wing ribs.
2003-12-29   4.5   -  Deburring the wing ribs
2003-12-30   1.5   -  Deburring the wing ribs.
2003-12-31   3.0   -  Deburring the wing ribs
2004-01-01   3.5   -  Deburring the wing ribs.
2004-01-02   3.0   -  Deburring the wing ribs.
2004-01-03   5.5   -  Finished deburring the wing ribs.
2004-01-10   4.0   -  Straightened all wing ribs
2004-01-15   2.0   -  Drilled wing conduit holes.
2004-01-17   4.0   -  Assembled the right wing skeleton.
2004-01-18   7.0   -  Assembled the left wing skeleton.
2004-01-24   5.0   -  Prepare the wing ribs for priming.
2004-01-25   7.0   -  Primed the wing ribs.
  68    hours

Left Wing
2004-01-31   4.0   -  Riveted left wing skeleton.
2004-02-01   2.0   -  Finished riveting left wing skeleton.
2004-02-09   2.5   -  Fitting the top wing skins.
2004-02-15   2.0   -  Fitting the bottom wing skins.
2004-02-21   2.5   -  Fitting the leading edge.
2004-04-24   5.5   -  Wing skin preparation and assembly (debur).
2004-04-25   2.0   -  Wing skin preparation and assembly.
2004-05-01   3.0   -  Wing skin preparation and assembly.
2004-05-02   3.5   -  Wing skin preparation and assembly.
2004-05-05   3.0   -  Wing skin preparation and assembly.
2004-05-08   4.5   -  Wing skin preparation and assembly.
2004-05-09   2.0   -  Assembling the leading edge.
2004-05-11   1.5   -  Installing the leading edge.
2004-05-12   2.0   -  Installing the leading edge.
2004-05-15   2.5   -  Riveting the top skins.
2004-05-16   2.0   -  Riveting the top skins.
2004-05-22   2.0   -  Riveting the top skins.
2004-05-23   2.0   -  Riveting the top skins.
2004-07-11   8.0   -  Riveting bottom skins.
2004-07-14   2.5   -  Preparing the bottom skins.
2004-07-15   3.0   -  Riveting bottom skins.
2004-07-17   2.0   -  Riveting bottom skins.
  64    hours

Left Fuel Tank
2004-02-24   1.5   -  Fitting the attach angles to the spar.
2004-02-28   5.5   -  Fitting the attach angles to the baffle
2004-02-29   3.0   -  Fitting the tank skins.
2004-03-06   2.0   -  Preparing the tank stiffeners.
2004-03-07   2.5   -  Preparing the tank stiffeners.
2004-03-20   5.0   -  Fabricate the tank attach bracket.
2004-03-21   4.0   -  Finish fabricating the tank attach bracket.
2004-03-22   2.0   -  Prepared the capacitive fuel gauge senders.
2004-03-23   2.0   -  Final preparations before Pro Seal - cut hole.
2004-03-24   2.0   -  Final preparations before Pro Seal - access cover.
2004-03-25   2.0   -  Final preparations before Pro Seal - fuel cap.
2004-03-27   2.0   -  Final preparations before Pro Seal - dimple skins.
2004-03-28   3.0   -  Final preparations before Pro Seal - dimple skins.
2004-03-30   1.0   -  Final preparations before Pro Seal - fuel vent.
2004-03-31   2.0   -  Final preparations before Pro Seal - more fuel vent.
2004-04-02   3.0   -  Final preparations before ProSeal - honest!
2004-04-03   3.5   -  Assembling and sealing the tank - First ProSeal!
2004-04-04   6.0   -  Assembling and sealing the tank - First Rib.
2004-04-07   1.5   -  Assembling and sealing the tank - Second Rib.
2004-04-10   3.0   -  Assembling and sealing the tank - Ribs 3-4.
2004-04-11   7.0   -  Ribs 5-6, capacitive senders, fuel vent.
2004-04-14   2.5   -  Assembling and sealing the tank - Last Rib.
2004-04-15   1.0   -  Assembling and sealing the tank - Final goop.
2004-04-17   8.5   -  Assembling and sealing the tank - Baffle.
2004-04-18   2.0   -  Assembling and sealing the tank - Access Cover.
2004-04-19   1.0   -  Assembling and sealing the tank - Leak Test.
2004-04-20   0.5   -  Assembling and sealing the tank - Leak Test.
2004-04-21   0.5   -  Assembling and sealing the tank - Leak Test Passed.
  79.5    hours

Left Flaps and Ailerons
2004-05-24   1.0   -  Installing the aileron brackets.
2004-05-28   1.0   -  Preparing the aileron brackets.
2004-05-29   4.0   -  Priming the aileron and flap parts.
2004-05-30   2.0   -  Installing the aileron brackets.
2004-05-31   2.0   -  Installing the flap brace.
2004-06-02   1.5   -  Flap hindge.
2004-06-04   2.0   -  Flap hindge.
2004-06-05   4.0   -  Flap and Aileron parts.
2004-06-06   4.0   -  Deburr flap and aileron parts.
2004-06-07   2.0   -  Deburr aileron stiffeners.
2004-06-08   3.0   -  Deburr aileron stiffeners.
2004-06-09   2.0   -  Aileron bellcrank and pitot tube.
2004-06-12   5.5   -  Flap and aileron preparation.
2004-06-13   5.0   -  Flap and aileron preparation.
2004-06-15   2.0   -  Flap and aileron preparation.
2004-06-16   1.0   -  Flap and aileron preparation.
2004-06-18   3.5   -  Aileron assembly.
2004-07-04   5.5   -  Aileron assembly.
2004-07-05   3.0   -  Flap assembly.
2004-07-07   2.0   -  Flap assembly.
2004-07-10   6.0   -  Flap assembly.
  62    hours

Right Wing
2004-08-12   2.5   -  Started riveting the right wing skeleton.
2004-08-14   4.5   -  Right wing skeleton in the stand.
2004-08-15   4.0   -  Fitting the bottom wing skins .
2004-09-19   3.5   -  Wing skin preparation and assembly.
2004-09-25   5.0   -  Wing skin preparation and assembly.
2004-09-26   6.0   -  Assembling the leading edge.
2004-09-29   2.0   -  Assembling and installing the leading edge.
2004-10-02   4.5   -  Riveting the top skins.
2004-10-03   4.0   -  Riveting the top skins.
2004-10-29   4.0   -  Fitting the bottom wing skins.
2004-10-30   4.0   -  Riveting the bottom wing skins .
2004-10-31   4.0   -  Riveting the bottom wing skins.
2004-11-02   2.0   -  Riveting the bottom wing skins.
2007-04-22   3.0   -  Inspection covers and Rats.
2007-05-20   1.5   -  Touch-up right bellcrank.
  54.5    hours

Right Fuel Tank
2004-08-17   2.5   -  Assembling the fuel tank (Z-brackets).
2004-08-18   2.5   -  Assembling the fuel tank (Z-bracket nutplates ).
2004-08-20   3.5   -  Assembling the fuel tank (drill ribs, fit tank).
2004-08-21   3.0   -  Assembling the right fuel tank (countersink rear baffle).
2004-08-22   1.5   -  Preparing the right fuel tank (cut stiffeners).
2004-08-24   2.5   -  Preparing the right fuel tank (stiffeners and fuel cap).
2004-08-25   3.0   -  Preparing the right fuel tank (T-405 tank attach angle).
2004-08-26   1.5   -  Preparing the right fuel tank (access cover).
2004-08-28   3.5   -  Preparing the right fuel tank (fuel pickup, access cover).
2004-08-29   8.0   -  Preparing the right fuel tank (Final prep).
2004-08-30   0.5   -  Preparing the right fuel tank (Fix screwup).
2004-08-31   2.5   -  Assembling and sealing the right fuel tank (stiffeners).
2004-09-01   3.0   -  Assembling and sealing the right fuel tank (first rib).
2004-09-03   3.0   -  Assembling and sealing the right fuel tank (three ribs).
2004-09-04   5.5   -  Assembling and sealing the right fuel tank (cap senders).
2004-09-05   4.5   -  Assembling and sealing the right fuel tank (end ribs).
2004-09-06   6.5   -  Assembling and sealing the right fuel tank (rear baffle).
2004-09-08   2.0   -  Assembling and sealing the right fuel tank (access cover).
2004-09-09   0.5   -  Leak testing the right fuel tank.
2004-09-10   0.0   -  Leak test passed.
  59.5    hours

Right Flaps and ailerons
2004-10-06   1.0   -  Installing the aileron brackets.
2004-10-08   3.0   -  Installing the aileron brackets.
2004-10-09   3.0   -  Preparing to prime the aileron and flap parts.
2004-10-10   2.0   -  Preparing to prime the aileron and flap parts.
2004-10-11   5.0   -  Preparing to prime the aileron and flap parts.
2004-10-15   3.0   -  Preparing to prime the aileron and flap parts.
2004-10-16   5.0   -  Priming the aileron and flap parts.
2004-10-17   4.0   -  Installing the flap brace and aileron gap fairings.
2004-10-19   2.0   -  Ailerons (right, 1 each).
2004-10-21   2.5   -  Assembling the right aileron.
2004-10-23   7.0   -  Assembling the right flap.
2004-10-24   2.0   -  Fitting the right flap and aileron.
  39.5    hours

Fiberglass
2004-07-31   2.5   -  Left wing tip.
2004-08-01   5.0   -  Left wing tip.
2004-08-07   6.0   -  Left wing tip.
2004-11-21   3.5   -  Right wing tip.
2004-11-26   3.0   -  Right wing tip.
2004-11-28   2.0   -  Right wing tip.
  22    hours

Fixtures and stands
2004-02-08   15.0   -  Building the wing stand.
2004-02-14   1.0   -  Building the cradle.
2004-07-18   3.0   -  Building the wing storage rack.
2004-07-24   3.0   -  Building the wing storage rack.
2004-07-29   1.0   -  Finished the wing storage rack.
2004-11-07   6.0   -  Building a paint stand..
2004-11-14   1.0   -  Finished building a paint stand.
2007-05-19   1.0   -  Build another mini wing stand.
2007-05-27   1.0   -  Got rid of the old wing stand.
  32    hours

Paint
  0    hours