Mike hostage's Builders log for the Pioneer IId
1991
12 Mar 0.8 Clean up speed brake area
13 Mar $21 New stapler
2.0 Glue spar edge of lower left wing skin (root piece). Scarf middle and outer left
lower leading edge skin panels
14 Mar $12 Tire inner tube, for making bands for tightening the wing skins down.
0.5 Removed staples from 13 Mar gluing
2.0 Glue ribs and leading edge spar to skin of lower left wing. Made clamp out of
3/4 square X 3" pieces of wood, with notch cut out, to clamp wing skin to
leading edge and provide surface for clamp to fit on. Won't work on upper
skin because the notch needs to fit on the edge of the leading edge spar
15 Mar 2.0 Remove gluing clamps from left lower inboard skin (leading edge). Dress up
glue edge. Glue middle lower leading edge skin. Glued both spar and
ribs/leading edge in one operation
16 Mar 1.3 Remove clamps and staples from previous gluing. Glue outer lower left leading
edge panel on left wing
17 Mar 0.4 Pull staples, remove clamps from outboard lower skin piece
31 Mar 2.2 Cut rear inner (lower left) ply panel, trailing edge ply pieces and 2 1/2 " and
5/8" strips for lower left wing. Glue rear inner lower left panel
3 Apr 0.4 Remove staples from left lower rear panel
13 Apr 0.3 Trim ply from around the left lower spoiler
14 Apr 1.3 Fit miscellaneous ply pieces (spoiler outline, outer elevator trailing edge
juncture, aileron trailing edge hinge line). Trim for gluing
1.3 Glue miscellaneous ply pieces. Cut all lower left cap Strips
15 Apr 1.0 Trim cap strips. Pull staples from previous gluing
0.5 Make feeler gauge for marking ply overhang at trailing edge and root spar.
Trim elevator ply trailing edge overhang
20 Apr 1.0 Glue cap strips on lower left wing
0.5 Draw some of the cut-out lines for radius-trimming of the lower left skin
2.5 Trim/radius ply edges lower left wing skin
21 Apr 1.3 Draw remaining radii lower left wing, remove staples from cap strips. Cut (jig
saw) remaining radii from ply skins. Hand finish some of the ply radii.
24 Apr 0.5 Complete radii and cutout hand finishing
28 Apr 0.5 Finish root edge of ply (to 1/4" overlap)
READY TO WORK RIGHT WING
11 May 3.0 Clean up garage, hang left wing from ceiling, mount right wing assembly on
table
0.5 File out openings in ribs 7-12, for rear spar
12 May 1.0 Cut 1/4" square braces for rear right ribs. Glue 1, 7, 20, 21 to right rear
16 May 0.5 Test fit rear right ribs 2-6 to main and rear spars
17 May 0.8 Glue ribs 2-6 to right rear wing
18 May 0.6 Test fit rear outer spar, ribs 8-12, cut tip rib off, have to re-glue it, it was on at
wrong twist angle. Should be no twist
19 May 1.2 Glue ribs 8-19 and re-glue tip rib
0.7 Cut Out Strips for framing spoiler box
20 May 0.5 Cut 1/4" bracing pieces for rear outer and inner spar. Taper to proper angle (bevel the edge). Rotate wing trailing edge down
22 May 1.0 Glue rear inner and outer spars to rear ribs
25 May 0.8 Trim inner and outer spar junction pieces plus work 5/16" outer spar buildup
pieces
0.8 Glue 5/16" strips to outer spar
26 May 0.7 Glue aileron hinge pads and inner/outer spar junction pieces
27 May 1.5 Glue elevator hinge pads and lower leading edge spoiler parts. Leave trailing
edge until after hinge holes are drilled (lesson learned from first wing!)
0.5 Trim lower leading edge spoiler assembly holes (glue drippings)
0.9 Flip wing over, reverse ends to work top side of right wing. Trim excess from
inner/outer rear spar junction. Begin planing trailing edge spar to fit rear end
of rear ribs
0.5 Popped tip rib loose at railing edge spar (while scarfing spar), re-glued
28 May 0.2 Begin scarfing top side of outer right rear wing spar
30 May 0.8 Finish planing inner/outer spar junction (top side) and outer spar 5/16" filler
strips
31 May 2.0 Hinge elevator and aileron for right wing. Begin fitting and trimming trailing
edge for middle Section
0.7 Glue upper leading edge of spoiler box. Glue filler to lower 3/32 sheet for
middle trailing edge section
2 Jun 0.3 Scarf and glue lower mid-section trailing edge to rear of ribs 7- 12
3 Jun 1.3 Scarf, bottom trailing edge glue assembly (mid-section) scarf top skin piece, glue
in place
4 Jun 0.4 Trim edges of rear trailing edge mid-section, sand and plane to extended
trailing edge of aileron and elevator
7 Jun 1.0 Assemble spoilers, upper and lower for right wing
9 Jun 1.5 Drill mounting holes for upper right spoiler. Glue upper and lower rear pieces
for right spoiler
15 Jun 2.5 Scarf and glue lower inside leading edge skins
0.5 Scarf middle and outer leading edge ply pieces (bottom) right wing
16 Jun 1.5 Glue middle lower leading edge ply on right wing
22 Jun 1.0 Cut, scarf and glue patch on skin, lower leading edge at rib 9. One layer of
plywood pulled loose in trimming excess glue. Also, glued outer lower
leading edge skin all for right wing
23 Jun 1.0 Pull staples outer panel, plane and sand leading edge of leading edge ply
27 Jun 0.6 Cut/scarf/trim and repair piece of lower right wing, at root. More pull-up of
ply skin due to excess glue drippings. Fitted patch to top and sanded flush.
Also placed oversized patch on underside of skin to strengthen the area.
29 Jun 0.7 Glue root repair, outer trailing edge section, lower right wing
6 Jun 0.8 Scarf and fit 45"X60" panel. Glue right rear inner panel, also small patch at
right root.
7 Jun 2.0 Glue panel at rear inner and outer spar junction. Also, glue spacers on rear of
rear spoiler cross piece, to provide surface for sheeting. Also, cut 1/2", 1 1/4"
and 2 1/2" steps for remainder of right lower surface
9 Jun 0.5 Remove staples from rear spar junction plywood and trim filler pieces on aft
edge of lower right spoiler cross piece
3 Aug 0.5 Glue skin around spoiler
4 Aug 1.5 Fitting cap strips
5 Aug 1.8 Glue cap strips. Mark trim radii
6 Aug 0.5 Jig saw trim cutouts from right lower wing
7 Aug 0.3 Trim sand cutouts
10 Aug 1.4 Finish trim sanding cutouts
11 Aug 1.0 Start assembly of jig to hold carry through structure for reaming of spar pin
holes.
1 Sep 0.7 Trim center carry through fittings for right wing main spar attach points.
7 Sep 0.3 Drill out 5/16 pip pin holes in rear spar carry through tube and fittings
15 Sep 2.7 Jig wings to mate with carry through structure. Initial results: main spar
fittings were tightened to the point where the plywood compressed and the
overall spacing between the two fittings was lessened. Thus the main spar
knuckles on the carry through structure had to be trimmed. With carry through
holes lined up (more or less, had to use under sized bolts to hold in place) rear
spar carry though appears to be approximately 1/2" low on the rear spar.
Symmetric error on both wings. Also, leading edges were not parallel and
appear to have a few inches of sweep. Solution: initially, will trim the main
spar carry through knuckles another 1/32-1/16" to allow more adjustment of
angles. Will then see, with the wings properly jigged up on a datum chalk line
on the ground, whether the spar carry through holes can be reamed enough to
take care of any mis-alignment errors.
16 Sep 0.8 Used sanding disc to trim knuckles. Above plan seems to be working.
Remains to be seen whether the reamer can adjust for the slight misalignment at the
spar fittings.
21 Sep 1.5 Fit right and left spar root fittings to carry through. Ground knuckles to allow
rear carry through to match trailing edge root fittings.
22 Sep 1.0 Fit elevator horn to elevator torque tube. Grind fitting to match left rear spar
14 Oct 1.0 Cut 3/32 ply Spacers to adjust position of rear spar fitting. Cut 4130 sheet into
new blanks for rear fittings. Glue spacers in place. Rear carry through
structure is sitting about 1\2" forward of rear spar. This necessitated moving
the forward fitting forward and building up the rear fitting to meet the face of
the carry through bar.
19 Oct 4.0 Garage clean-up and reorganization. Hung cabinet. Put table in center of
work space. Jigged wings again. rear attach fitting 1 3/16" from edge of hole
to edge of spar. Left needs 3 pieces welded to it, right needs 2 pieces welded.
Will have welding done by Hibbard Iron Works
19 Nov 2.8 Bolt (temporary) hinge pieces on ailerons and rear wing spar. Drill and fit
right wing aileron belcrank tube. Had to grind outer aileron hinges on both
wings as well as third hinge on right wing, to fit next to sheeting. Need to
mark each hinge or swap them around for best friction fit, then mark to keep in
same place. Need to shim third hinge on right aileron to fit
9 Nov 1.0 Cut bearings for ball swivels at aileron horns. Masked aileron horn holes. Fit
linkages into wing. Took 4130 stock to Hibbard Iron Works to get shims
welded on
23 Nov 3.0 Drill and fit both trailing edge spar fittings. Wings jigged to have O degree
sweep at leading edge- Met Danny Chou (107 Fern Cove Ct) who talked about his
plans for a man-powered helicopter. He offered to find literature for wing tip
designs
24 Nov 1.5 Fashion wedge shaped washers from aluminum block, for aileron horns.
Needed to allow bolt to be Parallel to bottom of aileron and bearing surface at
the top. Drill ailerons. cut aileron drive tube guides from 3/4" PVC
26 Nov 1.0 Cut, fit, trim ply pads for spoiler pulley tubes and a spacer for the third hinge
on right aileron (to line up the hinge holes). Also, fit both ailerons on with
3/16 bolts to check fit. Glue on pads