05-26-08 - Finishing Right & Starting Left Aft Spar
(I'm generating the pages from 5-26 to 9-1 on 9-12-08 so I'm going to
try and comment what I remember. We'll see how this goes...)
I spoke to Kerry @ Sonex about fixing my drilling mistake on the right
spar attach plate. He suggested replacing the one rivet that
I misdrilled with a bolt and centering the final size hole over both to
make up for the offset holes. I marked a piece of scrap with the
two hole centers to see if that would work or if I would need to remake
the components.
I drilled two holes in a peice
of scrap that are space the same as the incorrectly drilled part.
I updrilled the bracket to check it against the attach plate.
I up drilled the hole in the spar channel and used sand paper wraped around an old drill bit to "ream" the holes to match.
To compensate for the curve in the corner of the angle I'm working on a spacer that matches.
I'm replacing one of the middle rivets with a bolt to make up the
offset. This spacer is gonna get tossed - its not close enought.
All of the bolt and rivet holes match drilled. Not perfect, but
good enough. As I've been told by Kerry - the plane is
over-designed to compensate for variance in builder techniques.
The clecoed right aft spar. Ready to be updrilled to #30.
The attach plate updrilled to #30.
Updrilling the doubler plate for the aileron control rod hole.
The two holes on the left stay at #40 until match drilling the
ribs. Those with a good mental picture of how the wing goes
together will realize that I've got the doubler plate on the wrong side
of the spar channel. I've done that just for ease of drilling and
I've matched the radius of the channel on the botom of the plate.
Match drilled, deburred & scotchbrited.
All of the right aft spar parts ready for priming.
Next verse, same as the first... (except I'm not going to read the wrong detail and misdrill this one.)
The beginning of the left aft spar channel. I cheated a bit
to lay out this channel - it is a mirror of the right channel after
all...
I just clamped the right channel to the front of the left one and
marked the hole location. Why measure it four times when two
is enough? (Measure twice, cut once)
Marking the hole for the aileron control rod and doubler plate.
Marking the end of the channel for the attach plate.
Marked for the attach plate.
Perfect. I drew centerling lines that go through the rivet holes to align the plate correctly.
Match drilling the attach plate and aft spar channel to #40.
The attach plate on the left hand spar goes on the back of the channel instead of the front like the right.
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