Wagabond build

I finished all the rib tapes and span tapes on the top side of the wing. Cleaned everything up and brushed another coat of poly brush over the tapes, let this dry for a couple days and flipped the wing. On the bottom side of the wing I finished drawing the tape locations. I brushed a coat of poly brush on the tape areas then glued down the inspection rings, strut and inspection panel plates. Once it was dry I started with the rib tapes, gussets, and then onto the span tapes. Brushed poly brush over the tapes and when it was dry I started heat smoothing everything, which is the tedious part. Finally sprayed two cross coats of poly brush on. I let this dry for a few days before I flip it over.
 

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I flip the wing top side up and sprayed two cross coats of poly brush and let it dry for a couple days. Next was two cross coats of silver(poly spray) on the top. I had a few tape edges to smooth down, but no air bubbles anywhere. After this dried I wet sanded the top of the wing, cleaned everything up and sprayed the final coat of poly spray. I used an soldering gun to burn holes for the nav light housing and the fuel tank cover.
 

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On the bottom side of the wing I sprayed two cross coats of silver and after a day I wet sanded it and sprayed the last cross coat of silver. I burned all the screw holes and drain holes in the bottom of the wing and finally sprayed 3 coats of daytona white on the bottom.
 

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I flipped the wing top side up and sprayed 3 coats of Daytona white and let it sit for a few days. I taped off for the leading edge trim on both the top and bottom of the wing and sprayed 3 coats of true blue. Finally I cut out the inspection panels, inspection rings and outlets for fuel and nav lights. I believe this wing is done.
 

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Thanks, It came out pretty good. Waiting for weather to clear up to take it to hangar. I am going to have to cover ailerons and rudder next because fabric is on back order for other wing until beginning of July. I should have enough to cover those and elevators at home.
 
So I moved the wing to the hangar and took home both ailerons and the rudder. I cleaned everything up and brushed two coats of poly brush on. I got fabric glued on both sides of the ailerons and the rudder. I cleaned up all the glue seams on the left aileron and got the fabric shrunk down. I am working on cleaning up the glue seams on the rudder and the other aileron. I used two pieces of fabric on the ailerons because I had fabric pieces just big enough to cover one side at a time and I didn't want to wait for fabric that I ordered to come in. Its a little more work but keeps things moving along.
 

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I finished cleaning up the glue seams on the rudder and got the fabric shrunk down. Then I finished gluing the fabric down on the right aileron. After cleaning the fabric with MEK on the left aileron and rudder I brushed on poly brush, marked and punched holes for rib stiches and applied reinforcement tape. Then I did single stiches for both left aileron and rudder. I am cleaning up the glue seams on the right aileron. Also I got my struts delivered from univair today.
 

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I got the right aileron rib stitching done, soaked all the reinforcement tape with poly brush and then drew out all the locations for finishing tapes. Progress has been a little slow with summer and plus being hot in the shop, especially when doing the ironing. Next I brushed a coat of poly brush on all finishing tape areas and applied all the rib tapes. The wells on the ailerons were the hinges are are a pain to get into, time consuming. I preshrunk some fabric for the odd gusset areas and the hinge ribs on the ailerons and got these laid down. Then I ironed down the rib tapes where the span wise tapes go and just started to apply those tapes.
 

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I finished applying the span wise tapes, did a little ironing to smooth out the bigger wrinkles. I also got the trailing edge and leading edge tapes applied to the aileron and rudder. I heat smoothed a few things down, especially the bias tape on the trailing edge of the rudder at the nav light, which never wants to lay right. Next I poly brushed over all the finishing tapes. I then went over all the tapes and pinked edges with the iron and made sure everything was smooth. I spayed the 2 coats of poly spray and let it dry for a day and then did 2 cross coats of poly spray (silver), one a day. After a day of letting everything dry I wet sanded both ailerons and the rudder. I did have to iron down one small pinked edge and one spot on a finishing tape that I must have missed or lifted when I was spraying.
 

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After cleaning all the surfaces I sprayed the last coat of poly spray and let it dry for a day and flipped the ailerons and rudder and sprayed the other side. After two days I sprayed the poly tone Daytona white, I did two coats on one side in the morning and the final 3rd coat late at night, gave this a few days and then flipped everything and did the other side. I will move these back to hangar and bring home the other wing sometime during the week. Moving along.
 

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Got the ailerons and rudder moved out, cleaned up the shop a bit and brought the left wing home. Cleaned up the wing, wired the ends for the land, taxi, and nav lights. Installed the pitot and static hard lines from butt rib to probe. Then I installed the rivnuts on butt rib for wing fairings. I applied two coats of poly brush on the leading edge, trailing edge, and on rib cap strips. I applied some anti chafe tape and put in the inter rib bracing tape. Next I brushed on two coats of epoxy varnish on the wing tip bow. I gave this a couple days to dry and positioned the top fabric in place and glued down the leading edge fabric 2 inches.
 

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Thank you, I appreciate it. It's amazing how my views this thread has had and how many people have been watching from day one. I finished gluing down the top fabric at butt rib, land light, tip bow, and around the fuel tank. I cleaned up and ironed out the wrinkles on the glued area and flipped the wing. The aileron well takes some time and is the biggest pain to smooth out. Once flipped I tacked down the leading edge, glued down the trailing edge, and the butt rib on the bottom fabric.
 

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The aileron well is time consuming. Looks great. I use to glue around the landing light until I uncovered a Super Cub that had never been recovered before. I noticed that Piper covered over the landing light and then cut it out after the wing was painted. After I started doing that it saved so much time and I didn't have to have a dope proof black paint in the light well.
PXL_20231005_170059389.jpg
 
Thank you, I appreciate it. It's amazing how my views this thread has had and how many people have been watching from day one. I finished gluing down the top fabric at butt rib, land light, tip bow, and around the fuel tank. I cleaned up and ironed out the wrinkles on the glued area and flipped the wing. The aileron well takes some time and is the biggest pain to smooth out. Once flipped I tacked down the leading edge, glued down the trailing edge, and the butt rib on the bottom fabric.

I will hopefully start on covering in the next few months, and this thread will be referenced many times! At the point I am with my rebuild, I am amazed at the work you have done on this scratch build! Inspiring for sure.
 
Just finished looking through this whole thread. Very impressed! Thanks for taking the time to put all this up here. I'm just starting and this will be a valuable resource for me!
 
I never knew that about pipers, I figured the more glued down the better. I also try to get a inch of glue around the light and tank plus the wrap around, probably overkill. The aileron wells are tough because the iron will not sit flat anywhere on them and if you heat them too much you can pull the fabric straight off that curve. I'm glad this thread and photos will help. I was searching the web all the time when I started to build to get photos and ideas for the build. That is how I came to this group because ever the restoration photos in here of pacers and colts helped to interpret some things on the plans. Thanks again for all the compliments.
 
We glue around the perimeter of the light where the aluminum retainer strips go. Made quicker, cleaner work of it. Same way we do the aileron cut outs. I always hated tucking the fabric in and getting it to lay down.
 
I finished cleaning up the glue seams on the bottom of the wing, flipped it over, and glued down the overlap on the leading edge and tip. Cleaned and ironed all these seams down and then heat shrunk both sides down 250 and then 350. The top of the wing was cleaned with MEK and then I brushed on a coat of Poly brush. Next I measured, marked, and punched holes for the rib stitches. Flipped the wing over and cleaned the bottom with MEK and brushed on a coat of poly brush.
 

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On the bottom of the wing I marked holes for rib stiches, punched them, and applied the reinforce tape to rib cap strips. I flipped the wing and forgot to take a picture of the bottom. On the top side I did all the rib stitching, cut the reinforce tape 1/2 from the last stich, cleaned all the stitching areas with paint cleaning solvent to get wax and dirt up. Next was brushing a coat of poly brush on all the finishing tape/gusset areas, soaking the reinforcement tapes pretty well. I laid all the cord wise finishing tapes and gussets in a wet coat of poly brush. I will have to iron down where the cord wise tapes will go next before laying those down.
 

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On the top side I got all the span wise tapes laid down and smoothed out a few places with the iron and brushed a coat of poly brush over the finishing tapes and gussets. I flipped the wing over and cleaned up the reinforcement tape and rib stitching. Next was gluing down the inspection rings and inspection panel frame. I then brushed poly brush on the finishing tape and gusset areas. Once dry I laid the gussets and finishing tapes over the ribs, heat smoothed the areas for the span wise tapes and started laying those down. I did all the single rib stiches for the two ribs under the fuel tank.
 

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On the bottom of the wing I finished applying the span wise tapes and gussets, then brushed all the tapes with a coat of poly brush. Next was heat smoothing all the tapes and gussets down. Then I cleaned the bottom of the wing with paint cleaning solvent and sprayed one coat of poly brush. After letting it dry for 2 days I sprayed the 2nd coat of poly brush. I will let this dry for a few days and flip the wing over to the top side.
 

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Merry Christmas to all. Before the holiday I got the wing flipped and heat smoothed all the tapes on the top side. Then I sprayed the 2 coats of poly brush on about a day apart. I sprayed the first cross coat of poly spray, let it dry for a day, and then sprayed the 2nd cross coat on the top side of the wing. I let this dry for 2 days and then wet sanded with 400 grit and scotch brite pads, and finally sprayed the 3rd cross coat of silver.
 

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Todd, I guess you're carrying the wing in and out of a spray booth each coat ? or doing it right there maybe. Fine work either way... :)
 
I do all the work right there in the shop. It is a 2 and 1/2 detached garage behind my house. I have a filtered exhaust fan at the rear wall and a filtered box with a fan in the center for filtering the air and a screen for the man door. Using a HVLP gun and spraying at about 16 to 20 PSI the over spray is not that bad. Yes I do get build up on everything over time but dust and other stuff from grinding, wood working, and everything else too. About every year I clean the entire shop and power wash the floor. Its a good excuse to go through everything and toss out junk and organize. I finished the bottom with poly spray, wet sanded and sprayed the last coat of silver. Waited a few days and sprayed 3 coats of Daytona white on the bottom. I let this dry for a few days and flipped it over and sprayed the top 3 coats of Daytona White. Gave this about a week to dry and then taped off the leading edge for poly tone true blue.
 

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Beautiful work as usual!! I have just ordered all the fabric and supplies, but they were out of stock of the Poly Spray. The recommended amount at Spencer is 10 gallons of Poly Spray, which seems like way too much. How much Poly spray did you end up using?
 
Yes, 10 gallons is way to much for this size aircraft. I used about a gallon and half per wing. About gallon for the 2 ailerons and rudder. Still got horizontal stabs, elevators, and fuselage to go. Approximately 2 gallons per wing for poly brush, you use more of this by putting down finishing tapes and brushing it on. I used about a gallon per wing of poly tone.
 
There was finally good weather to move the wing out of the shop and to my hangar, it was either to wet, to salty, or to snowy. Plus I had to let the back yard dry up to get to my trailer. I painted the last of the interior panels above the doors. Next I made up and welded together the two aileron stops. I cut out window openings in the inspection panels at the aileron cable connections near the wing roots. Also I made up the two steel straps for the tie down rings. This was all cleaned up and epoxy primed, along with the lift struts.
 

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Not much of a update, I've been getting some home spring projects knocked out. I did get enamel Daytona white sprayed on the lift structs, aileron stops, wheel covers, and a few other inspection panels.
 

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