Front spar on HS, number 2

This time I got it right with the new parts. The 8 degree bends also became much strighter and at the right place with the small break from Clas Ohlson. Using a mallet to create the bends, as described in the manual, works but is very inaccurate.

Regarding primer, I need some washing/etching thing before applying the WG 6650 wash primer. At Aunes Karosseri they have never heard of such a thing, but another car paint specialist could get some DuPont/Corlar 5717S Metal Conditioner. He could only get 6 l, and I have to purchase all of it because it is something they never use. When reading the technical manual of the 5717S, it is meant to be used on ferrous metals and some other. Aluminum is not mentioned, so I am not sure if this is the right product at all. Monopol in France say I should use something called DERINOXALU, but have not been able to get it yet.

Priming

Purchased a net at Biltema and put in on the primer table. Heard from Van's, the new parts will be here in a couple of days.

More primer

The wash primer, WG 6650 from Monopol, turns out to be one layer of several. Got in contact with the factory and the procedure for airplanes is:

• Clean with acid solution and water
• Apply WG 6650 Wash primer, one thin layer (10-15 micrometer dry)
• Apply P 05 Strontium Chromate Epoxy primer
• Top cote(s)

On the inside P 05 Strontium Chromate Epoxy is enough (no need for the wash primer). Air France and Eurocopter use this method and these products. The wash primer is used for other applications also (cars, trucks, boats), but with different epoxy primers on top depending on the application.

But, my RV is not going to fly several hours a day, seven days a week, year after year, and it is not going to fly shuttle traffic to oil installations in the North Sea year after year. On the other hand, my airport extends out into the sea, and according to technicians working there, it is a very corrosive environment. Tomorrow I am going to hear about price and availability of P 05, will se how it goes.

Still waiting for the new parts, it has been very quite from Van's.

Set up the primer booth more properly with a separate compressed air line with pressure regulator and water removal, purchased at Biltema. Built a primer table (235X53X75), only lack the chicken net. If the P 05 Strontium Chromate Epoxy is going to be used I will also need some more substantial ventilation than door/window, at least a fan.

The WG 6650 wash primer contains Zinc Oxide and some phosphates of some kind.

Primers

Got some wash primer from Monopol (Wash Primer WG 6650) from a local car body shop. I allso got a rattle can of "houshold" metal primer (Quick Universalgrunning from Scanox) which is an alkyd based primer with corrosion inhibitors (supposedly).

The wash primer is green and the other one is gray. SB means Scotch Brite has been used on that area. It is possible (but hard) to scratch both off with my nail on the area not scuffed with scotch brite. The area scuffed with scotch brite is much harder to scratch off. I have to use a knife or a sharp object and I take off just as much aluminum as I take off primer, so it is very tough. The "houshould" primer seem to be just as hard as the wash primer. Zinc oxide and some orthophosphate?? seems to be the active anticorrosive ingredients in both.

One major difference is that the wash primer has a smoother and more shiny surface, and the coating is thinner (the last thing could be me sprying).

Small problems

Did some mistakes on the front spar of the HS. Three of the holes connecting the spar and HS-410 were too close to the edge (1-2 mm max). Also two of the holes for the rib was drilled in the wrong positions resulting in edge problem. Although not neccesary according to more experienced people than me (including Van's), I decided to re-do the front spar. I am now waiting for new parts.

The priming problem has come back. It turns out that Zinc Chromate is not a legal substance anymore due to toxic reasons, and therefore is nowhere to get hold of. Right now etch primer from a local shop specializing in aluminium constructions is something to be investigated.

The storage room to be used for priming is painted white to get it as light as possible.

Deburred ribs

Deburred the ribs on the HS this evening.

Front spar on HS

Front spar on the HS is finished bent to 8 degrees, drilled and deburred.

Forward HS spar ready for drilling

The spars and HS-410 is cut, marked and clamped ready for drilling. Have to figure out which size drill first.

Received a mail from Van's about the rivets in the HS-409. They shall go in aft to fwd.

HS-410

HS-410 is cut to shape and deburred.

Shopped alot of clamps, hand saw, files and some other stuff at Biltema. Received some e-mails from the insurance agency. Still no solution there, but things are moving forward.

Fwd spar on the HS

My tech counsellor couldn't make it this evening, so I did some other stuff. I started on the front spar by drawing the cut lines on the spars and the HS-410. To finish the cuts I need a hand saw. I also need some more clamps and files, so tomorrow I have to go to Biltema - again.

I noticed that nowhere do the drawings or the manual specify that the HS-410 is to be made from the AS3-063X6X12 sheet, this has to be deduces from the available parts. When the house is literally packed with available parts, this should be specified properly. Another thing is that it is not specified if the rivets holding the aft spar and HS-409 together is to be riveted from fwd to aft or the other way around. This may not be important - or - it may be obvious - or - it may be obvious that it is not important... I don't know, so I have sent a mail to Van's.