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Last Updated 16 Jul 2006

29 Jan 2005 - matchdrilled the splices at the ends of the main spars.

30 Jan 2005 - Primed the end pieces, rivetted them on, and got to work with the J-Stiffeners.  Got the left spar match-drilled. Also noticed a flaw in the left spar. We'll see if it matters. (Long since given up the Grand Champion image for this plane.)

Spliced ends of the spars.

Look at the spars again.

Cutting the J-Stiffeners.

J-Stiffeners clamped in place on the left spar

Close up of the 1/16" offset.

Yours truly working on matchdrilling.

The spar (left) came with one hole on the end oblonged and primed. Not sure what I think about that. (Not sure how much this hole matters. Question is in to Van's)

Closeup of the screwed up hole.

Match drilled left spar.

 

31 Jan - 3 Feb 2005 - Finish match drilling the J-Stiffeners and the rest of the #40 holes. Van's confirmed the spar was good to go (just wanted to check...) Then built a jig and started countersinking the nutplate rivets. Got all the nutplate rivet holes completed on the right spar. The jig is 3 pieces of 2X4 screwed together (Nails work loose WAY to quick) and another two 2X4's (one shaved a little on one edge) joined lengthwise with shims to support the flange as you countersink. Seems to be working well.

One side of jig

Back of jig with moveable support. Note the shims underneath the support.

Otherside (reverse angle) of the support.

Side view of basic jig.

 

4 - 9 Feb 2005 - Countersunk the spar flanges. Ended up clamping the spar to the workbench after Rick Sked hurt my feelings about the jig. (Actually, it was just taking to long sliding the spar through) Anyway, finished countersinking, deburred the opposite side, and got the fuel tank skin attach nutplates on one of the spars.

Look at all those countersinks...

Spar with nutplates

Closeup of nutplates clecoed on

Me riveting the nutplates on the flange

 

10 Feb 2005 - Finished installing the nutplates, countersinking, and priming.  Broke my 3/32" countersink doing the stuff on the end of the spar. At least it was the last countersink. Couldn't finish the tie-down brackets, since I can't countersink the rivets for the nutplates. Also, found this rivet head on the floor. Since everyone knows I don't screw up rivets, figured it must have gotten stuck on my shoe while I was at Rick Sked's... :)

BIG countersink holes...

Countersinking the nut holes

Tiedowns waiting on countersinks

Rick's drilled out rivet

 

Off to the Wing Ribs!!