First Lower Wing Done

It's been a loooooong time since I uploaded a video to my YouTube channel (Aviation Fanatic) or posted anything here. Why? Well, I was procrastinating big time because of the aileron well (my name for it). That's the aluminum piece on the rear of the wing where the aileron fits in. Anyway, I wasn't looking forward to forming that piece. As it turns out, I was right to be afraid. It was tough!

Although it ended up requiring some filler, it didn't turn out too awful. Between a straight edge, a carpenter's square, the pipe I used on the leading edge, and a hammer, my friend Mike and I got it done. For the other lower wing, I think I'll try some angle iron from a bed frame.

Obviously, there's no aileron. There are a few pieces that I'll need to machine to get that mounted.
They're called "spigots." Other than that, the right lower wing is done.

Here's a closeup of the aileron fit into the aileron well. It's not mounted;
I just placed it there to get an idea of how it fits. Not too bad.

Second Wing Done!

Go to my aviation YouTube channel to see some videos about the process of building this wing. This wing went faster than the first one and turned out better. I guess you should expect to get better as you do things more. The blue spots all over the leading edge is body filler to fill in any dents or depressions, as the metal is very thin and virtually impossible (for me, at least) to end up with no dents. It looks kind of crazy in these photos, but the leading edge is very smooth and level.

My New Engine—Tearing Down the Corvair

My new Corvair engine. This crankcase and the heads (actually, just one) will be
powering my Super Baby Great Lakes.

Bell housing off. A fifth bearing will be replacing this.

The crankshaft on top and camshaft on the bottom. The propeller will bolt onto the top shaft.

One of the two carburetors. My airplane engine will have only one carburetor and will be mounted below and to the rear of the engine, similar to a Continental or Lycoming.

Removing the engine oil apparatus (I don't know what it's called).

The alternator. My engine will use a John Deere alternator.

oil filler, etc.

Mike, holding the fan shroud. Check out the giant mice nest!

Magnesium fan and mice nest. I'm about to discover that mouse urine does major damage to aluminum.

Removing the harmonic balancer with a flywheel puller, $13 at Harbor Freight.

Again, the oil pump case (or something along those lines) on the rear of the crankcase.

The alternator. I'll send this in as a core and get a rebuilt one with points and electronic redundancy.

Having fun with my plane.

Pressure washing things. It didn't really help all that much.

After removing the fan and oil case cover. You can see the pistons, rods, and crankshaft in there. Cool stuff!

I convinced my wife to try out the impact wrench. She was nervous on the first one...

...but then thought it was cool. She did all the nuts on that cylinder head. I later learned that you're not supposed to use an impact wrench for this. Use penetrating oil and a hand tool so you don't apply too much torque and damage the case studs.

All twelve nuts off the case studs.

Push rods, rocker arms, and baffles.

Removing the cylinder head.

One of the baffling clips off and looking at the push rod tubes.

Head coming off.

Head off, push rod tubes coming out, cylinders awaiting removal. They slide right off.

The head and its combustion chambers. Each cylinder has a gasket right where Mike's finger is pointing, not a single gasket like most car engines.

Bottom of the engine with the oil pan removed.

This is the bottom of the half of the engine where the mice had their giant, cushy home. Notice all the corrosion?

I couldn't get this head off. I thought maybe the push rod tubes were stuck and so I cut them all in half.
That didn't help.

Tapping on the head wouldn't get it off, so I went ahead and undid all the rod caps and cracked the case. That left me with just the side of the case with the stuck head.

The camshaft.

The crankshaft, hydraulic lifters, and remaining case half, cylinders, and head.

This head was stuck big time. I ended up banging on the rod ends to try and use the pistons to drive the head off. One of my swings was off a bit and ended up hitting the crank case with the hammer. See next photo.

My damage to the case. I'm hoping this can be repaired.

Massive corrosion, clogging of the fins, and damaged fins. Damn mice. I'm sure this head is a write off. Hopefully I can just pay a core and get a rebuilt head without sending one in.

The culprit. This is why the head wouldn't come off. One of the case studs is essentially welded to the cylinder head. Another adjacent one is similar but not this bad.

To get the head off, I ended up cutting two case studs with a cutoff wheel on my angle grinder. Apparently, removing these from the case is a tricky job best left to a professional, or you risk damaging the case. I need to send my case halves to have them machined for three-liter pistons and fifth bearing anyway, so I have no motivation to mess with these.

First Wing Done!

Truth is I have a tiny bit of sanding left to do, but that shouldn't take more than a few minutes. I'm going to post a video summarizing some highlights about building this wing and a possible major piece of rework that I'll decide about after building the other three wings. I'll be starting on the upper left wing pronto. I'll be documenting that build with video, so there probably won't be any posts here for a while.

(By the way, the wing weighs about 21 pounds.)