24 – Wing Tips Part 1

Initial Fit

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I used a Dremel cutting disk to trim the wing tip flanges.


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Vans have changed the method to align the wing tip trailing edges … rather than using a template, having fixed the flap in its reflex position, and aligned the aileron TE with the flap TE, you simply align the tip TE with the aileron TE.


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I clamped the flap and aileron together.


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I used temporary packing pieces to help shape the wing tips for the initial fit.


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Once the wing tip trailing edge is strapped to the wing leading edge as per the manual advice, the tip flanges push snugly against the wing skin edges.

I have read that other builders have had issues with the tip TE’s aligning with the ailerons, but thank goodness mine seemed to align very nicely.

I used straight pieces of wood to clamp the wing tip TE to the aileron, ensuring nothing moved as I match drilled.


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Match drilling starts at the leading edge, working aft and alternating top/bottom.


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Lots of holes to match drill!


Trailing Edge

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One of the last jobs fitting the tips will be to trim the trailing edges to match the ailerons.

As you can see, there will be a sizeable width to remove, so …


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… I decided to add a flox mix inside the tips at the trailing edge to improve/maintain the joint strength after trimming.


Nutplates

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After final drilling the holes to #27 …,


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… I used a bolt/nut to clamp a nutplate in position for match drilling the nutplate attachment holes.


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I machine countersunk the #40 holes by hand.


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And then clamped a jig with a #27 hole to anchor the #6 countersink bit pilot.


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Because of the flange step, I used a spacer to keep the countersink tool perpendicular to the flange surface.


There are a lot holes, so it took a while!

But once done, it was a quick job to rivet on the nutplates.

I tried to be as careful as possible when match drilling for nutplate attachment to ensure no holes migrated during the process … this would obviously effect the tip alignment if it did happen.

I screwed on the tips when complete and with bated breath peeped at the TE’s to check alignment … happily all was well : )

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