# FRED #528 construction log

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#### Abraham Leket

##### Well-Known Member
Wing tip (DRW8) and ply gussets: to my complete surprise this task tured out to be rather hard to produce-part of it can be attributed to the cold temperature (50-60F) and the slow curing of T88 under the gussets. In short- its a summer job to do it quickly.
We start with 3 triangles- the picture depects the items- ply covers,spruce sides and ply gussets-1:1 from the plan:

They are glued to Rib #10 like so (#4 is the rear spar):

The 1/2" spruce tip bow is bended wet on top of the triangles- clamps are used for 72 odd hours -otherwise it will spring back since its not supported by gussets yet:

(2) Center grip bay large 1/16" ply gussets are constructed. The small inner wood blocks will support the inner 1/16" ply-later on:

The 1/2" spruce wing tip is well supported by gussets to create a firm base for the tip and to ease the Ceconite covering- much later on. Note that at this point-the aileron has been cut-off from the wing. Its time..

Still more gussets complete the tip construction, note that the center hand grip bay is now inside covered with 1/16" ply-this will prevent dust entry when all covering is done. The wing gets 2 large 1/16" ply covering in between rib #7 and rib #8-they support the covering in the aileron 3/32" cable exit points:

The lower 1/16" ply cover gets its pullies inspection panel door:

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#### Abraham Leket

##### Well-Known Member
One good picture of wing tip triangles and hand grip was somehow left behind- so-I'm posting it. I'm using this post to post my decision to cover the aileron with 1/32" ply top and bottom surfaces. Ceconite will go on top of it later on. Why ply cover? - well.. according to FAA recent study..naaa forget it ... I had (1) 48"x48" 1/32" ply sheet left over- its a shame not to use this fine ply- thats why.

The wing root (3) triangles and hand grip:

The aileron covered:

#### Abraham Leket

##### Well-Known Member
Wing root-1/16" ply skin- Some of the close up pictures of FRED construction logs (way in the past) depicts some questionable practices stems from the need to conserve ply. I'm talking web direction and Eric Clutton specifically mark the ply web direction needed in the wing root.
The only way to construct it in the true web direction is by purchasing a whole 48"x48" 1/16" ply sheet and deal with the cutting accordingly i.e- web direction- as DRW8 indicates. (1) 48"x48" whole sheet will cover one wing root area (top & bottom).
The following is the skin on top of the root:

The bottom ply cover needs to have a recess for the aileron pip-pin insertion on each and every wing fold session so we cut 7"x4" opening (6"x4" in the plan but we are much bigger these days..) and add a door,a hing and secure its opening with either the prefered Dzus product or magnet- like in the picture). This is done on the bottom skin before gluing it (I've been using Dremel wood cutting wheel throughout FRED's construction- the straight lines of the opening in the ply skin can attest that its the right tool ..)

The bottom root cover can now be glued (note web direction at 45 degrees):

Thats it folks! Port wing fully completed. The Starboard wing will be just a mirron image of the Port wing construction that I've presented in the past 4.5 month. so it will not be posted in the log.
See you all in April 2016- after starboard wing completion and - for the first airframe inspection before covering- done by the Israeli Aviation Authorities.

Happy new year everyone!

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#### Abraham Leket

##### Well-Known Member
DRW19-Flying wires and fittings: All it takes is a solid 5/8 4130 bar and the following tools:
1/4-28 LH tap, 5.9mm drill, 14-28 Die:

The 2" 5/8" bar is drilled with 5.9 mm and taped both end with 1/4"-28 LH. The 7.5" and the approximated 62" flying wires get the 14-28 die both ends:

The 1.75" fittings are also drilled and taped 1/4-28 LH.
You get the universal joints by grinding one end to accept the flying wire tabs in the fusalage:

The long 62" also receive 5/8" plugs that later will be grind in the middle to attach to the wing fittings:

The attached thumbnails depict the (2) sets require" the lower 7.5" with the 5/8" turnbuckle (at the left ) with its winding hole("tommy bar"), and the top 62" 1/4" flying wire set:

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#### Abraham Leket

##### Well-Known Member
DRW22-Pitot tube: While constructing the starboard wing you meet the following little job- constructiong a retractable pitot tube- the pictures depicts the process:

The pitot tube is retracted when the wing folds:

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#### Abraham Leket

##### Well-Known Member
Landing light- : The starboard wing gets a VERY powerfull 12V LED projector (good for 25,000 hours...) to be used constantly. (will be covered with clear Lexan later on-

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#### Abraham Leket

##### Well-Known Member
Fuselage rear section cover: The bottom cloth is a certified 2.7 OZ to take all the abuse from stones and weeds and it is done first. The 1.7 OZ sides follow and top covering comes last and its also the non-certified 1.7 OZ superflight.
The tapes are either 3" wide or 1" wide-depends on the area. ,
The covering process is not an easy one and it requires a LOT of patience. Picture is tilted 90 degrees for some reason.For orientation note the rudder cable white exit fairing. Sorry about it.