I started today by working on the wingtip
thinking I could easily get this done in one
As you can see the plastic wingtips
require a lot of cutting to trim up.
Here's the aft piece mostly done. When I
went to fit this piece, I realized that I
can't fit it until the wing trailing edge is
on. I can't install the trailing edge until
the wing is riveted so I'll wait on the
So then I moved on to thinking I could
finish up this leading edge corner skin. The
skin gets clecoed or riveted to the bottom
of the wing (as seen here) and then folded
up and around.
Once I folded it up and around the fit
was so bad that there is no way I can use
this skin! Zenith tried to precut it but
they just aren't even close.
My plan now is to get some of that thin
poster cardboard and make a template and
then make my own skin. That way it will be
custom fit and will match perfectly. I
didn't get any photos of how bad this skin
fits, but it was bad!
I did make this little clip that goes on
the leading edge.
As you can see here I drilled holes in it,
then cut slots to make tabs so it can be
bent to match the curve of the wing.
Here it is drilled to the rib.
Just to kill some time, I match drilled the
access plate to the bottom of the wing.
Then I countersunk the holes...
...so that I can use countersunk screws. I
think it will just look nicer than having
big screw heads poking out into the wind.
Surely I will pick up an additional 25 mph
in cruise with my flush screws!