Title: 22-03 - Hinge Bracket and Main Rib Preparation
Initial Prep (Debur, Trim, Drill, and Cut) 4/30/23 - 1.7h 5/1/23 - 0.4h 5/6/23 - 0.5h This step is really a continuation of the previous one. It starts by separating the main ribs into top and bottom sections, and cleaning up the cut edges. There is also a part that is separated into two doublers for the aileron spar after the #40 holes in the doubler are countersunk. The rib parts and doublers are easy to debur and prepare for dimpling, countersinking, priming, and assembly. [Band Saw, Hole and Edge Deburring Tools] Final Prep (Dimple, Countersink, and Shape) 5/2/23 - 1.2h Dimpling and countersinking requires some care in this step to ensure it is done correctly. A technique to make the countersinking easier is to cleco the hinge brackets together back-to-back, and then countersink both exposed faces. In addition to ensuring the correct side is countersunk, the extra thickness of the cleco'd parts makes a good pilot hole for the countersink cutter. Dimpling took a little thought since the instructions in the plans don't completely agree with the drawings. The plans specify dimpling the .098 (#40) holes in the ribs, which are the flange holes. However, the drawings show the #30 holes in the rib web getting dimpled. The flanges don't get dimpled for a couple more steps, but I went ahead and did them now since they are not used later for match/final drilling. I also dimpled the rib webs as shown in the diagrams. [Pneumatic Squeezer, #40 Reduced Diameter Dimple Dies, #30 Dimple Dies, Microstop Countersink Cage, #12 Drill, #30 Countersink Cutter, #40 Countersink Cutter, #12 Countersink Cutter] Prime 5/1/23 - 0.5h 5/6/23 - 0.7h I leaned forward a bit too much in the last step and primed the inboard and outboard hinge brackets before countersinking them in this step. A quick primer hit on the countersinks in this step, and all is good! I also employed my standard priming technique (cleaning/scuffing, degreasing, and priming) on the main ribs. The cleaning / scuffing happened before dimpling the ribs, then degreasing and priming after the parts were completely prepped. [Grey Scotchbrite Pads, Bon-Ami Cleanser, Dupli-Color Degreaser, Rust-Oleum Automotive Self Etching Primer (Green – Rattle Can)] Assemble 5/7/23 - 0.6h This step, like the previous one, finishes by attaching the hinge brackets to the corresponding ribs. The squeezer has good access to all of the rivets, especially since the ribs don't have a bottom flange. I started by riveting the small A-1007-1C doubler to the A-1007-1B inboard hinge bracket, and then I riveted the inboard and outboard hinge brackets to the ribs as shown in the plans diagrams. One thing to keep in mind is the bottom two holes of each hinge bracket is unriveted for now, since the bottom flange of the main ribs has to go there later in the build. [Pneumatic Squeezer, Flush Squeezer Dies]


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