Date: Tue, 31 Aug 1999 07:55:22 -0400
From: John Cooper <snopercod@CITCOM.NET>
Subject: closing ES wings
To: lancair.list@olsusa.com
Message-id: <3.0.5.32.19990831075522.00906a00@mail.citcom.net>
Mime-Version: 1.0

          <<<<<<<<<<<<<<<<--->>>>>>>>>>>>>>>>
          <<  Lancair Builders' Mail List  >>
          <<<<<<<<<<<<<<<<--->>>>>>>>>>>>>>>> 
>>
I don't know if this applies to the ES wing, but Clarence & I both closed
out our L-235 wings using a 1" x 4" aluminum box beam (flatwise) on the
bottom under the fwd spar, another 1" x 4" aluminum box beam (edge wise) on
the bottom under the aft spar, and a pieces of 2" x 2" wood on top held
together by deep-throat C-clamps holding the fwd and standard C-clamps
holding the aft. (However you do it, make sure you perform a dry-run before
you apply the Hysol to make sure you have everything on hand that you will
need.)

To make the deep throat C-clamps, take some standard 8" C-clamps to your
local weld shop and have them cut out the center section and weld up a 12"
deep "C" section where the measly little 4" throat used to be.

The aluminum box beams fit into the jigs under the top spar cap and aft
spar, and the 2x2s went over the opposing locations on the bottom of the
wing. Needless to say, the 2x2s on top were covered with duct tape as a
release agent.

To capture the Hysol sqeezeout inside the tank (where accessible) I gently
taped duct tape along the fwd and aft spars where the sqeezeout would ooze
down, then left a 3' tail of duct tape (folded back on itself so no
adhesive was exposed) sticking out of the fuel filler. We had one person
mixing Hysol, and the other spreading. Then both of us applied the skin and
the clamps.

After the skin was clamped tight, I slowly pulled out the duct tape and the
excess Hysol with it.

I used the same Hysol-removal technique on the fwd D-section of the wing.

Guess that's why my empty weight is 958# (no radios). Eat your hearts out,
guys!
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
LML homepage:   http://www.olsusa.com/Users/Mkaye/maillist.html