Finished riveting everything to the rear spars… almost.

Finished riveting all the stuff to the spars…

I really struggled riveting the aileron hinge brackets to the spar. Couldn’t get the squeezer in there. My rivet set wasn’t long enough to clear the bracket. So I had to use the offset rivet set. But that one is thicker and interfered with the bracket rivets. Mangled a bunch of rivets and drilled them out. Ended up mangling the bracket and bending the doubler drilling out one of them. Thankfully the spar was undamaged.

I drilled out all the rivets and disassembled the brackets and doublers. The hinge is fine. Emailed Van’s to send me a new doubler and angle bracket.

On the other wing I had the brilliant idea to try shooting the rivets for the hinge bracket from the other side of the spar. This worked a lot better.

Should have replacement parts by next weekend when I get back from Florida.

Today’s Time (hours):	2.0
Wing Time (hours):	65.0
Total Time (hours):	276.0

Rinse, repeat, right spar complete

Match drilled the J channel to the spar.

Machine countersunk the nutplate attach holes.

Riveted in the nutplates

Countersunk the screw holes.

Machine countersunk all the skin attach holes.

Riveted in the nutplates at the tip end of the spar.

Riveted the doubler to the spar and installed the tank attach nutplates.

Final drilled, deburred, scuffed and primed the aileron bell crank brackets

Installed and torqued the aileron bell crank brackets.

Right spar done!

Today’s Time (hours):	4.5
Wing Time (hours):	21.5
Total Time (hours):	232.5

Left spar complete

Riveted the spar to the doubler with the 5 AN470 rivets using the squeezer. Then shot the tank attach nutplates using the gun.

Final drilled and deburred the left aileron brackets.

Scuffed and primed the aileron brackets with rattle can.

Installed and torqued the aileron brackets to the spar.

Put up the left spar and moved the right spar to the bench. Hopefully I’ll get that one knocked out tomorrow.

Today’s Time (hours):	1.0
Wing Time (hours):	17.0
Total Time (hours):	228.0

Countersunk ALL the holes

Countersunk the tank attach screw holes.

Installed the inspection plate nut plates and countersunk the screw holes.

Countersunk all the skin attach holes.

Installed the snap bushings and the the four nutplates at the tip end of the spar.

Today’s Time (hours):	2.0
Wing Time (hours):	16.0
Total Time (hours):	227.0

Installed left tank attach nut plates

Final drilled #40 all the nut plate rivet holes.

Machine countersunk the nut plate rivet holes

Riveted the nut plates.

Lots of nut plates.

so. many. nut plates.

Today’s Time (hours):	2.0
Wing Time (hours):	14.0
Total Time (hours):	225.0

Started the wing build

Screen Shot 2019-05-27 at 10.10.58 AM

Cut the J channel to the specified lengths with the Dremel tool and a cutoff wheel.

Clamped the J channel to flange leaving it 1/16″ proud of the flange.

Drilled and clecoed the J channel.

Flipped the lower J channel to the upper flange to finish the holes where the nut plates were on the lower flange. I marked the J channel and set aside for later when the skins go on.

Today’s Time (hours):	2.0
Wing Time (hours):	12.0
Total Time (hours):	223.0