Intermission

I'm have a lot of trouble finishing the ailerons.  The last step is deceptively simple -- insert the lead weights and install screws to hold them in place.  Unfortunately, there is no way to apply back pressure to the nut plates in which the screws thread, and without back pressure it is very difficult to get the threads to engage.  I've ruined the AN509-8R16 screws that came with the kit. I ordered new ones from Aircraft Spruce, but they use the new designation and I ordered the wrong sizes.  (yes, sizes--plural.  I want some screws that are a tad larger than called out to try a few tricks.).  I'll document the issue in more detail when I get it finished.

As is typical for me, when I have a problem or am facing a "don't screw this up!" task, I often take a break and do something else for a while.  I find that it lets me ruminate on the problem and reduces the risk of doing something out of frustration and making it worse.  This weekend is one such example, hence the title of today's posting.

Remember back in June 2013 when I built a toolbox as a practice kit?  (No, you don't.   But you can go read Metal has been bent; Rivets have been placed for reference.)  That tool box and a second one have been accumulating miscellaneous small tools for 13 years.  Van's isn't selling that practice kit any more, but I got a different practice kit that's a lot more fun.

Light Box

Light Box in the dark

This is a very simple, straight forward aluminum box with Van's logo cut out from the front.  It's internally illuminated by a strip of LEDs.  The point of the kit is to learn how to work with aluminum sheet metal and rivets.   As mentioned in the 2013 post, I really didn't want to use driven rivets.  To be honest, I have been slightly afraid of driving rivets all this time.  I have a borrowed a rivet gun from a hangar neighbor and bought some accessories including a totally cool tungsten bucking bar.  (It's really fun to feel its heft as it's about 20 % denser than steel!)  I finally bucked rivets to build the box and it really wasn't a big deal after all.  I feel much better about the fact that I will be driving rivets to assemble the main wing spars in a month or so.

I also painted it. (duh!) I made it another learning opportunity by using two different brands of primer before painting.  I have a clear preference for one of them, so I'm glad I did it.

The second part of the intermission involves the tool boxes mentioned above.   When I started building this month, I just had a bunch of tools moved from the hangar and thrown into a new tool chest.  They really weren't organized and just kind of thrown in at random.  I quickly ran out of space and yesterday I bought a second tool chest.   

Before:

two tables full of loose tools

After:

Two organized tool chests

Now that the light box is finished and the tools are properly organized, I'm going back to building.  I'll start on the flaps while I wait for the AN509-8R16's to arrive so I can finish the ailerons (eventually.)