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Horiz Stab  (2.0 hrs)

Continued deburring per Sec 8-6.   Lots of edges !   Began to work ahead on Step 4: fabricate 4 cradles.  Using 1/2 MDF board, since cuts easier w/ jigsaw than 3/8 plywood, and costs less.  

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Horiz Stab (4.5 hrs)

Sec 8-5   Step 1:  Rivet Front Spar, Doubler, and Caps (2).    Requires 5 different rivet types/sizes, so needed to follow the diagram explicitly.    Again, Main Squeeze works great, although arms get tired after this many 1/8 in rivets.

My woodworking clamps make great stands for the Spar while riveting.  

 

Step 2:  Finished the Spar with 9 rivets on top flange at middle in Countersunk holes, and 9 more on bottom flange.

Sec 8-6,   Step1:  Deburr Nose Ribs, Inpar Ribs.  20 total.   All edges including lightening holes take some time.  Good time to listen to some comedy podcasts !

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Horiz Stab (3.5 hrs)

Sec 8-4, steps 2 - 7:   For Doubler on Front Spar, Final Drill all the #30 holes, then  C.S the 12 specified holes.   With top and bottom Caps cleco'd, also CS the middle 9 holes on flanges.

Disassembled all parts to deburr all the holes (lots !)  Buffed the parts with 3M Scotchbrite, then cleaned with Acetone.   I was actually able to prime outside, since temp was unusually warm  (74 degrees ) for early March in central Illinois.   Nice to not have to set up and use the spray booth.

Ready to re-assemble and rivet per Sec 8-5.

Prior disassembly to scuff and prime....

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Mar 7, Mon

Horiz Stab (3.5hrs)

Sect 8-4:  Started Front Spar build with deburring all edges, including lightening holes.  Clamped Spar Caps precisely, drilled #30 holes & deburred.  Re-assembled again with clecos so could drill #40 holes on flanges.  Time consuming process.   Per instructions, completed for top Cap, then repeated process for bottom Cap.

Note significant filings from using deburr tool on edges.

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Mar 5, 2016

Horiz Stab  (4.0hrs)

Sect 8-2:  Steps 7-8.    Clean  doubler with acetone, then primed.    After drying, riveted to Rear Spar with AD470 4-6 rivets (36 of them !)   The Main Squeeze makes quick work of these rivets, but my arm was getting a little tired.    Pic below still has blue marks indicating where NOT to rivet at this time.

Sect 8-3:  Steps 1 & 2:  Drill, deburr, and rivet (6) the inboard hinge assembly with flange bearing captured between.    Jumped ahead to this page while waiting for primer to dry on doubler.

Sect 8-2:  Step 9:  Riveted 4 pairs of hinge brackets to spar.   (out of sequence, since I did these while waiting for primer to dry fully).

 Sect 8-3: Step 3.  Bolted inboard hinge to spar and doubler.   Used 28 in-lbs plus 14 in-lbs (friction drag for lock nut) per Sect 5-20 in manual.

Step 8-3:  Step 4:  Prep 2 Front Spar Caps and 2 Stingers for the Forward Spar.    Involves cutting off ends at angle, grinding to smooth finish, and deburring all edges.   Got into a rhythm so I felt a bit like a robot doing these edges.   Not pictured...

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Horizontal Stab  (2hrs)

Steps 5-7 completed.  Countersunk 2 holes that will be under center hinge brackets.  Used microstop with #30 CS bit.   Being cautious to not go too deep, I proceeded in small steps until just right depth.

Final Drill #12 holes in brackets.   Then deburred all holes and scuffed parts to be primed....tomorrow.

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March 3, Thurs.    (I'm back in shop after enjoying a month soaking up sunshine in Arizona !)

Horizontal Stab (3hrs)

Sec.  8 -02   Start of Horizontal Stab build.    Steps 1-4 done for Rear Spar with doubler and  hinge brackets (4 pairs).  I did the doubler for front spar while I was at it, too.    Lots of deburring edges (along 9ft + spar !) including all the lightening holes.   Small diameter 3M Cut and Polish wheel (1") in air drill made quick work of the holes.  A groove worn into wheel aids in slightly rounding the edges, too.

Final Drilled holes (reaming) in for doubler to spar rivets, and spar to brackets.