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RV-7 Construction Log
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Date:  4-12-2018
Number of Hours:  3.90
Manual Reference:  SB 14-01-31
Brief Description:  SB 14-01-31

Step 10 continued. Even with a 1.25” cutoff disk on a Dremel Micro, I couldn’t finish trimming the corner of the HS-702 spar flange with a cutoff wheel (as called for in the instructions) due to interference with the inboard section of the web. I ended up using a 1/16” diameter burr in my Dremel Micro. I added a 1/8” thick aluminum shim behind the flange to hold it off of the stainless, which allowed me to us the edge of a mill file to smooth the ragged edge left by the burr. I started deburring the edge and making the radii with a flat needle file, the finished smoothing the edges with 360-grit sandpaper.

Step 11. There is no step that says to cut the forward flange off of the HS-405 ribs, but it’s very obvious that it needs to be done before radiusing.

Step 12. Marked, drilled, and deburred the four pilot holes in the forward ends of the HS-405 main ribs as shown in Figure 5.

Step 13. Enlarged the forward most holes in both ribs. I don’t have a #27 drill, so I used a 9/64, which is only about 0.008 smaller. It’s not clear to me yet why these holes are being enlarged, but they need to be larger I’ll deal with it then.

Step14. Separated the HS-00001 spar doublers, and deburred the edges and lightening holes. Figure 6 shows the parts being joined 3/8” from a row of rivet holes, but the actual parts were joined 1/2” from a row of rivet holes. I almost marked and ground the edge back to 3/8”, but fortunately I noticed that there is one edge that is supposed to be 1/2”. I dodged a bullet on that one...
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After cutting with a small burr. Note that the flange is shimmed up from the skin.

After cutting with a small burr. Note that the flange is shimmed up from the skin.

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After Filing and Deburring

After Filing and Deburring

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HS-405 Ribs Trimmed, Radiused, and Drilled

HS-405 Ribs Trimmed, Radiused, and Drilled

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