Initial Prep (Debur, Trim, Drill, and Cut)
10/11/2021 – 0.9 hours
10/12/2021 – 1.6 hours
10/13/2021 – 1.2 hours
Deburring the rear spar doubler is pretty standard, but takes a little extra time because the doubler is a thick piece and the tooling marks take some additional effort to grind down. I used a flat file and curved file to reduce the tooling marks followed with 150 grit aluminum oxide sandpaper to smooth and debur the edges. I also used a small (1” diameter) Scotch Brite wheel in an electric drill to debur the large holes in the doubler.
The hinge brackets have #12 holes that are used to attach the rudder that get final-drilled at this point. I clamped each hinge bracket to the work bench to final drill each individual bracket. There are also several holes in the rear spar, doubler, and rudder hinge brackets that are final-drilled to #30 after all the parts are cleco'd together. I finished the drilling step by match-drilling two holes in the top bracket of the lower hinge attachment brackets. These final two holes take a little extra work because you are drilling through steel rather than thin aluminum. You definitely need a sharp drill bit, some drilling lubricant, and patience to drill these holes.
Preparation of the VS parts concluded by fluting the ribs, radiusing sharp edges of the nose and tip rib forward flanges, and final-drilling the rib-to-spar attach holes. I found that the nose rib holes are a little tough to get to with a standard drill and bit, so I used a 90 degree drill attachment for those holes. You could also use a long (12”) bit, but the angle attachment worked well for me.
[Hole and Edge Deburring Tools, Flat File, Round File, 1” Scotch Brite Wheel, 150 Grit Aluminum Oxide Sandpaper, #12 and #30 Drills, 90 Degree Drill Attachment, BoeLube]
Final Prep (Dimple, Countersink, and Shape)
10/11/2021 – 1.1 hours
10/16/2021 – 0.4 hours
10/17/2021 – 1.0 hours
The rear spar doubler is a relatively thick part and is prone to some bending during the manufacturing process. I removed the bend by clamping the doubler to my work bench and hammering out the bend with a rubber mallet. I sandwiched the doubler between the bench and a scrap 2x4 to hold the piece steady while I worked the bend out. I applied downward force to the free end of the part, and hit the part with light-to-medium force near the edge of the work bench. I then loosened the part, slid it to the next set of holes (about an inch), and repeated the process along the entire length of the doubler. I kept repeating this process until I managed to straighten out the part.
The flanges of the spar and ribs are dimpled after the holes are final drilled with the skin. The pneumatic squeezer with reduced-diameter dimple dies provided the best access to dimple most of the holes with very clean results. The two forward-most holes on the tip rib that were match drilled with the skin are too close together to access with the pneumatic squeezer, so I did those two dimples by hand with a close quarter dimple die and blind-rivet puller.
The final job in this step was dimpling the #30 holes in the rear spar and countersinking the corresponding holes in the spar doubler. The bottom section of the spar is flush-riveted on the forward side where it attaches to the aft fuselage.
[Rubber Mallet, Vise, Pneumatic Squeezer, #40 Reduced Diameter Dimple Die, #30 Dimple Die, Close Quarter Dimple Die, Blind Rivet Puller, #30 Countersink Cutter, Microstop Countersink Cage]