Bare Wing Ready for Cover

I have completed the covering of three wings. Since this is the last chance to document the wing structure, I decided a few photos of the 4th wing would be a good idea. Note that the plates which surround the interplane strut fittings are are non-standard and were added to assist with anchoring leather boots at each end of the interplane struts. The wood block at the nose of the root rib is also a modification. It works in conjunction with the root fairing which will be shown later.

Fabric Covering the Wings

A few photos of wing covering. They may not be in order.

This glue stripe is applied so the fabric can be trimmed without fraying.

Covering the Fuselage

What follows is a condensed glimpse of the fuselage covering process. We are using Stewart Systems Products. Detail videos of the proper technique for covering with their system can be found on their web site or on YouTube. We tried to follow their procedure as faithfully as possible.

 We covered the bottom first in the inverted position. All of the final details for the control system were checked and double checked prior to closing up the bottom side.

Anti-chafe tape was used on the bottom stringers due to the extrapounding from the exhaust pulses and prop blast.

I didn't get many good shots of the bottom after covering but inspection covers were added below the elevator bell crank. Finishing tapes were added to all of the belly stringers. (not shown here)

Now for the turtle deck.

I decided to double-cover the turtle deck due to abuse from old guys getting in and out, etc..
This is the first ply of turtle deck fabric installed.

The right side fabric came next. First drape of fabric shown here.

In the process of attaching and trimming the right side fabric.

Here it is all glued, trimmed and tightened up. 

Now for the left side

Chief QA officer on the job!

All of the fuse fabric is now installed waiting for finishing tapes. Starting to look like an airplane!
The stool is supporting about 1lb. in this photo. Yikes! Glad the door is down, otherwise a breeze might tip it on its nose.

Split Boot Cowl for Better Access

As shown by the photo above, the Boot Cowl side panels were originally made in one piece. The tight fit around the front landing gear/flying-wire bracing combined with the slip fit of the side panels under the top panel made removal of the side panel very difficult.

To ease installation and removal, I sheared the panels into two pieces and rejoined the halves with piano hinge.

When the retaining fasteners are removed from the side panel the hinge pin can be pulled allowing removal and installation of the panel in two easy pieces.

The hinge joiner was flush riveted and will be virtually invisible.
Access here will be important as the avionics will be located behind these panels.

Center Section Sheet Metal

Sometime back the center section was modified to include a handle cut from 1/4" 6061-T6 using water jet.

I decided to replace the original sheet metal tank cover with a new one which would extend back and tie into the handle.

The original plan also included access doors for each of the spar to fuselage fittings plus gap fairings to cover the space between the root rib and the center section. I decided to streamline things by using one-piece fairings to serve as access port covers as well as root gap fairings. There is a very small weight gain (again!!) but not much as the doors and the gap covers are eliminated. I still need to cut out the sheet metal in the center or open area of the handle.

Wood filler blocks were fitted and attached to the root ribs and blended to the contour of the center section around the leading edge and extending under the bottom of the wing. This will leave a very small gap at the nose of the root rib which can be covered with color matched tape. The GlaStar wing root is done this way as well as many gliders.

Here's the cut out for the grab handle in the center section.