Main and rear spars for the left wing are now substantially done. An EAA Technical Counselor visited and he went over every rivet with a flashlight and magnifying glass. He said my work was good but still found about twenty rivets to drill and replace. Having done that, I feel more confident about both the riveting and replacing rivets. Most of my problems were with the factory head. I learned that short rivets require less pressure than long rivets of the same diameter. And one long burst is better than three short bursts.
When bending the spar flanges on the brake, it's important to pay attention to maximum bend radius as well as minimum. I exceeded the maximum and thus impacted internal parts dimensions. But Bob approved my fix and so I pressed on.
Basic sequence after the spar flanges were bent as follows:
Layout and mark front and rear spars together. Stack and clamp the cap strips together in position. Triple and quadruple check all marks and measurements.
Drill cap strips undersized using drill guides for plum holes. Cut and stack spacer bars at rib locations, lock into place and drill undersize holes with drill guide.
Spar attach and splice plates were difficult to cut using MDF template and flush router technique. Mostly cut these pieces with table-mount jig saw, hand saw and files.
Remake pieces as necessary to get good fit.
Cut lightening holes in main spar on drill press with fly-cutter.
Assemble the spars vertically mounted to bench, now with all pieces in their correct locations, front and back.
Cut rib attach angle blanks. Drill the rib attach holes only. Then bend the attach angles.
Using tape, square and clamps, drill the attach angles to match the spacer bars and cap strips.
Now that all pieces are in place (excluding wing strut attach fitting and its rib attach angles) , go through and drill to final size holes.
Disassemble, deburr and prep all pieces. Treat with Stewarts Eko Etch and paint with Stewarts Eko Prime.
Reassemble and rivet.
Flush rivet spacer to accommodate wing strut attach fittings.
Mark wing strut attach fittings and cut slot in spar flange.
Drill pilot holes for wing strut attach fittings. Hold in place with temporary screws.
Notch rib attach angles to fit over wing strut attach fittings.
This is where I will stop with the left main spar. When the time comes I will drill and ream the wing strut attach fitting holes for the AN3 bolts.
I'll also remake at least one of the rib attach angles over the wing strut attach fittings to get better edge distance for the ribs at that location.
Here's a short video of some highlights:
https://youtu.be/ibsnJjDfwvQ