04/25/13 - Spar Rivet Replace
Dan and I were looking over the rivets and Dan spotted a couple that were just OK. One in particular had a little angle on it, so after a short discussion we decided to give it a couple hits from the rivet gun and bucking bar to flatten it out. As you are probably thinking, …
04/22/13 - Test Assemble Spars Halves
Dan put the spar halves together with clecos and the five assembly holes mated really well. (We use wing nut clecos here because you can really draw them up tight.) Looking Good Return to Main Spar
04/21/13 - Finish Riveting Left Hand Spar
Dan & I worked on the inboard rivets. In this area the spar caps are the widest so one needs to pay more attention to the rivet gun and bucking bar. This is also where the flush rivets are. In addition there are angles on the spar web that make it thicker. This means longer rivets and for …
04/20/13 - Priming Assembly Start Riveting Left Hand Spar
During the week Dan finished up the spar cap preparation. Dan mixed up some Har-Hyde self etching primer and sprayed the left spar parts. I arrived just as they were finished drying, what great timing. Dan put a really nice thin coat on, notice how you can still read the red printing on the parts. We …
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04/14/13 - Cleaning LH Spar Parts For Priming
Dan & I took apart the left hand spar and prepped the parts from priming. Our method starts with deburring, then 3M (of course) 120 grit aluminum oxide sand paper, then 240 grit and a final pass with red Scotchbrite hand pads. It is amazing how many little scratches happen when you handle these parts so much. …
02/07/13 - RH Spar Riveting
Here are some pictures of riveting the right hand spar. The first picture is using a tungsten bucking bar we borrowed from a friend. It weighs a lot since the density is so awesome. This next photo shows a really difficult area to buck the rivets. Not even the little tungsten bar would fit between the angles. …
- Main Spar (right)
So many small details that we have documented with photos and emails back and forth but so few posts on the web site. We need a secretary…. In November of 2012 the right wing box was assembled for the first time and in December and January (2013) the ribs were match drilled to the spar, …
01/29/13 - Countersinking Spar
Dan spent a lot of time figuring out the proper countersink depth to allow the dimple to properly form over it. See this post Dan used the countersinking cage and bit where we could. We purchased it from Pan American Tools. On the spar cap the cage would not fit so we used the drill …
01/05/13 - Updrilling RT Spar
Dan updrilled the right spar. To do this we installed the bolts first. We spent a lot of time getting a “tight fit” for the AN bolts as stated on the plans . We bought a bunch of reamers to the right fit, sometimes we would need a .0005″ smaller reamer. (I have to admit this was …
11/04/12 - Spar Attach Block Locating And Match Drilling
11/4/12 – Dan got in the garage and match drilled some of the spar assembly. To locate the spar spar attach block, Dan made a pin to fit in the 3/16 hole in the attach block. He also made a #40 hole in one end this pin. With a #40 drill bit in this end we …
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