After holiday weekend, back to building. Discovered C01409-L Angle was incorrectly formed (stamped) by Vans or supplier. I followed Sect 38-11 instructions to separate LH from RH in single formed part, then ground edges smooth. Followed Steps 4 & 5 to flute flange until bottom flange was flush to level surface. But I noticed when lining up C01407-L Rail, it was "off" almost 1/8" from Rail's edge along center...AND it was now bowed along it's length. I performed same steps for symmetrical RH Angle, and it fit perfectly along Rail, aligning with it's edge as shown in Fig 2. Side by Side comparison revealed LH Angle has it's bend (stamped shape) at wrong distance from holes. Sterling at Van's product support checked their inventory, and although he measured 0.015" difference in LH vs RH hole locations from bend, its nowhere near the 0.125" delta on my part. Assume the metal did not stretch properly, or something slipped in forming. Van's is mailing a free replacement, and examining what happened in producing those parts, too. (bummed I spent 1 hr on bandsaw and grinder and another hour resolving - and Van's won't pay to expedite the part to me ). At least discovered prior to going any further. So...I worked on other parts such as Sect 38-13 Canopy Handles, and Sects 38-11 Step 6 machine c'sinking Canopy Rail Flange.
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| correct alignment in foreground on RH parts. Background shows 1/8" exposure of edge (blue) on Rail ...leading to flush at each end |
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| LH has too large bottom flange, with too short of vertical flange cleco'd to Rail |
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| Machine Countersunk specific locations for 3 and 4 size rivets |
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| canopy handles "done" (started from simple angle |