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Notes on Step 5: Looking ahead to Step 5 where it
calls for removing material to make a smooth transition
between skins, I believe I have found a good way to do it in
the method below. |
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 I
cut the blue plastic back about 2 1/2" and used my
Automotive DA Orbital sander. It allowed me to get a pretty
uniform taper. |
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 I
have a pad on it that uses a velcro back sanding disk and
works very well, better than the glue on. I got some various
disks starting at 80 grit and up to 320 grit. |

Before starting taper there is a pronounced edge. |

After a little work the upper edge becomes much nicer, you
can feel it is much smoother. Need to work it down a bit but
not get it to thin on the edge. The DA seems to give you
very good control on keeping the taper uniform. (Note the
underlying skin will also require a taper as per the plans) |
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 Step 1: Lay the
W-1028A Wing Box J-Stiffeners-Long and W-1028B Wing Box
J-Stiffeners-Short into the J-Stiffener cutout in the cutout
in the wing ribs. See the isometric view on Page 16-1. Cleco
the W-1002 Top Inbd Wing Skin, W-1003 Top Outbd Wing Skin,
and the W-1027A and W-1027B Wing Walk Doublers to the main
spar, rear spar and wing ribs. (Note that the outboard wing
skin overlaps the inboard.) Cleco the J-stiffeners to the
wing skins.

NOTE: DO Not
drill the aft most row of holes in each top skin. These
holes will attach the gap fairings in Section 20. |
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 Step 2:
Final-Drill #40 all holes common to the top wing
skins and spars, J-stiffeners, wing walk doublers and ribs.
NOTE: I made a small dot with a
Sharpie Marker when they are drilled. It only takes a minute
or two more so I can tell which ones are done.. I am going
to wipe the dot off as they are deburred , and it will tell
the ones that are deburred.

Final-Drill #40 the two holes that will be used to attach
the aft most inboard nutplate to the W-1002 Top Inbd Wing
Skin (holes are called out in Figure 1.) |
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 Step 3:
Final-Drill #19 the screw holes for the nutplate that
will be installed along the inboard edge of the W-1002 Top
Inbd Wing Skin as shown in Figure 1. Dimple the aft most
screw hole for a #8 flush head screw (See Figure 1)

Then machine countersink the rest of the screw holes for
a #8 flush head screw dimple.

Machine countersink all the rivet holes that
correspond to the W-1027A and W-1027 B Wing Walk Doublers
for the head of an AN426AD3 rivet. |
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 Step 4:
Disassemble the parts clecoed on in Step 1 from the
wing assembly. NOTE: I am deburring
wiping of the black dots I marked when they were
match-drilled. I am using my new deburring tool in the
cordless drill. I had a close look thru the magnifying glass
to compare the deburring done with it as compared to the
hand tool. It only takes a tiny bit off, but I think it
looks good and it definitely speeds
things up as it does both sides at one. |
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 Step 5: To
Make a more aesthetically pleasing joint between the top
wing skins it is permissible to remove material from
the edges of the skins as shown in Figure 2. Remove material
as shown in Figure 2, Section A-A from the top outboard side
of W-1002 Top Inboard Wing Skin and the lower inboard side
of the W-1003 Top Outbd Wing Skin to create a smooth
transition from one skin to another along the chord wise
portion of the skin joint. Remove material from the top
outboard forward edge of the to Inbd wing skin to allow the
top surface of the top outbd wing skin to be flush with the
top surface of the tank skin (use a scrap piece of A3-032 to
simulate the tank skin as shown in Figure 2, Section B-B

Prime all parts if/as
desired. I have switched to Sherwin Williams PSE 4600 two
part Epoxy Primer to try it out. I like it and am going to
continue to use it. |
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 Step 6:
Deburr the edges and holes of all parts. Dimple the W-1002
and W-1003 Top Wing Skins
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Dimple the W-1028A and 1028B Wing Box J-stiffeners (note
the screw holes on the inboard edge of the top Inbd Wing
Skin have already been machine countersunk or dimples in
Step 3). |
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Dimple the holes on the upper flange of the rear
spar and upper flange of all the the four inboard most wing
ribs. |
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