05-14-08 - Right Aft Spar

The inboard side of the aft spar needs to be trimmed at an angle. The plans just indicate the distance to the inside of the angle, not the degrees.

I made an initial cut with a hacksaw in preparation for cutting with snips. The hacksaw cut prevents the tip of the snips from tearing the metal in the corner.

Rough cut with the snips. The edge is a bit jagged so it needs to be dressed with a file.

Dressed with a file and sanded to remove all of the burrs/cut marks.

The outboard end of the spar needs to be cut down about 1/4". The kit ships two 96" rear spar channels and they are cut down to 95 3/4". I'm not 100% sure why they aren't 96" and the spar tip extensions aren't a 1/4" shorter, but I'm sticking with the plans.

I did the "hacksaw-the-corners & use-the-snips" method as was done on the inboard end.

I used a 2"x4" to line up the extension ends with the aft spar channel. The board is a snug fit inside the channel and provides a good reference to keep the channels lined up.

To keep the doubler/joiner plate straight in relation to the channel I drew a line 1/4" from the end of each channel and lined up the predrilled holes on the doubler.

Clamped for drilling.

Partially drilled to #40 and clecoed.

Completely drilled and clecoed to #40.

After a bit of filing and sanding the aileron doubler fit into the bottom of the aft spar channel. I sanded it enough to match the hole up with the hole in the channel.

Partially drilled to #40 and clecoed to hold the doubler in place so I can match drill the rib holes.

Marked and drilled to #40.

< Last Home Next >