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Pauls Web Site
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Date: 8-18-2013
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Number of Hours: 15.00
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Manual Reference: W08
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Brief Description: Finished Main Spars
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After taking a break from building to go to Oshkosh, I got back and resumed riveting the main spars.
I finished riveting a couple days ago, and spent yesterday thinking about how I was going to mate the spars. With the spars clamped together, the attach blocks have to be updrilled from 3/16" to 1/4". Fortunately my holes lined up almost perfectly. Unfortunately, even though I was step drilling only a 1/64" at a time, I still managed to oval one of the attach blocks. I think it may have been because I purposely dulled the bits too much, and ended up applying too much pressure the wrong way with my cordless drill.
I ended up putting the whole spar assembly on my drill press, hoping that the next two steps would remove enough material to correct the problem. Unfortunately the ovaling was too much to be fixed with the drill press and 1/4" drill. However, these attach blocks will eventually be updrilled to 3/8". I held a 3/8" drill bit agains the ovaled hole, and it looks like it will remove the ovaling, if I can manage to drill the final hole straight.
The good news is that I drilled the attach blocks on the other side with the drill press, and that hole came out perfect. So did the three alignment holes in between. I was able to use a drill guide for those.
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Ovaled 1/4" Hole
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3/8" Should Remove Oval
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Finally Done with Main Spars
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